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Full text of "Allis_Chalmers_Fuel_Injection_Pump_Roosa_Master_DM_Series_Parts_Catalog_"

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(ROOSA MASTER DM Series) 



service manual 



parts catalog 




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AVOID ACCIDENTS 



Most accidents, whether they occur in industry, on the farm, at home or on 
the highway, are caused by the failure of some individual to follow simple and 
fundamental safety rules or precautions. For this reason MOST ACCIDENTS CAN BE 
PREVENTED by recognizing the real cause and doing something about it before the 
accident occurs. 

Regardless of the care used in the design and construction of any type of 
equipment there are conditions that cannot be completely safeguarded against without 
interfering with reasonable accessibility and efficient operation. 



A careful operator is the best insurance against an accident. 
The complete observance of one simple rule would prevent many 
thousand serious injuries each year. 
That rule is: 

Never attempt to clean, oil or adjust a machine while it is in motion. 



H N 

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WARNING 



On machines having hydraulically, mechanically, and/or cable controlled equip- 
ment (such as shovels, loaders, dozers, scrapers, etc.) be certain the equipment is 
lowered to the ground before servicing, adjusting and/or repairing. If it is necessary to 
have the hydraulically, mechanically, and/or cable controlled equipment partially or fully 
raised to gain access to certain items, be sure the equipment is suitably supported by 
means other than the hydraulic lift cylinders, cable and/or mechanical devices used for 
controlling the equipment. 






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A 

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A 



FUEL INJECTION 
PUMP 

(ROOSA MASTER DM Series) 

service manual 

and 

parts catalog 



Form 73112988 English 



A 



WARNING 



STUDY THE OPERATION AND MAINTENANCE 
INSTRUCTION MANUAL THROUGH BEFORE STARTING. 
OPERATING, MAINTAINING, FUELING OR SERVICING 
THIS MACHINE. 



The Operation and Maintenance Instruction Manual provides the 
instructions and procedures for starting, operating, maintaining, fueling, 
shutdown and servicing that are necessary for properly conducting the 
procedures for overhaul of the related components outlined in this 
Service Manual. 

This symbol is your safety alert sign. It MEANS ATTENTION! BECOME 
ALERT! YOUR SAFETY IS INVOLVED. 

Read and heed all safety instructions carrying the signal words 
WARNING and DANGER. 

Machine mounted safety signs have been color coded yellow with 
black borders and lettering for warning and red with white borders 
and lettering for danger points. 



RAT-ALUS 



SUPPLEMENT NO. 5 

FUEL INJECTION PUMP 

(ROOSA-MASTER DM SERIES) 

SERVICE MANUAL AND PARTS CATALOG 

FORM 73112988 



( 



( 1-81 ) 



ATTENTION: Insert this sheet in the front of publication as record of receipt. Replace or add pages 
in the publication according to instructions below. 

Additional copies of this supplement are available. Please direct your request to: 
Fiat-AUis Construction Machinery, Inc., Publications Services Dept, 
3000 South 6th Street, Springfield, Illinois 62710 U.S.A. 

or 
Fiat-AUis M.M.T. S.p.A. - MAGAZZMO STAMPATI - Viale Torino, 
STUPINIGI (Torino) - Italy 



Replace the following like pages: 

1-7 (No change) 
1-8 (Revised) 



6-3 (Revised) 
6-4 (Revised) 

6-5 (Revised) 
6-6 (Revised) 

9-1 (Revised) 
9-2 (No change) 

9-5 (Revised) 
9-6 (Revised) 



9-7 (Revised) 
9-8 (No change) 

11-1 (Revise 
11-2 (No c> 

12-3 1&&A V <!? 
12-4 JA\?^ 

12 /T <** $A) 



4" ^9/iange) 



K 



& <? 



£ 



O 



v 



Revised) 
(No change) 



12-13 (No change) 
12-14 (Revised) 

12-25 (Revised) 
12-26 (No change) 

12-31 (Revised) C 
12-32 (Revised) V 

12-35 (No change) 
12-36 (Revised) 



REASON: Add spring colors ;Cb text; delete (not -used) speed light load 

advance information; add timing information, page 9-1; include 
additional calibration data, pages 9-3,9-6,9-7; add Fiat-AUis 
tool part numbers, page 11-1. 



Any/product change described in this publication is part of the continuing effort of Fiat-All Is to make Its product responsive to customer 
n<pra and is not to be construed as a field campaign. A product change may be incorporated with or without prior notice and without 
ligation to Fiat-Allls or Its affiliates. 



c 



( 



Fl 



FIAT-ALLIS 



SUPPLEMENT NO. 4 

FUEL INJECTION PUMP 

(ROOSA-MASTER DM SERIES) 

SERVICE MANUAL AND PARTS CATALOG 

FORM 73112988 



( 11-79 )/ 



ATTENTION: Insert this sheet in the front of publication as record of receipt. Replace or add pages 
in the publication according to instructions below. 

Additional copies of this supplement are available. Please direct your request to: 
Fiat-Allis Construction Machinery, Inc., Publications Services Dept, 
3000 South 6th Street, Springfield, Illinois 62710 U.S.A. 

or 
Fiat-Allis MM.T. S.p.A. - MAGAZZINO STAMPATI - Viale Torino^ 
STUPDUGI (Torino) - Italy 



c 



Write in the following changes: 

Page 5-16 (after STEP 18) 

A/OT£~ : /3& ^c/re -f-/7& governor 

color* of the ^/>w)j a//)fy co ] or /n 
Page 5-17 (add at bottom of first column - in STEP 



Page 12-3 
27 


74061781 


1 


Page 12-7 
27 


74061836 


1 


Page 12-8 
97 


74059667 


1 


Page 12-13 
27 


74061836 


1 


Page 12-14 
97 


74059662 > 


/ 1 


Page 12-19 
27 


74061836 


1 


Page 12-20 
97 


/4059662 


1 


Page 12?25 


74061836 


1 




correct - - CG/n/ttrc //?£. 






e 



SPRIN'X /? ^^ontrol (&JoLc^k Snocun) 

SPRINprfgc ,ernor control (&r>e,e.n -6)uc) 

*RING, outer advance (?c I I bus - Vc I low) 

SPRING, governor control (S tu t - £/u c) 

SPRING, outer advance (^Mc/f - & re en J 

SPRING, governor control (3/ue, - & luc) 

SPRING, outer advance (6/a.ck - £r-een) 

SPRING, governor control (SJtic- S/ue) 
(Continued) 

Any/product change described In this publication is part of the continuing effort of Fiat-Allis to make its product responsive to customer 
yto and is not to be construed as a field campaign. A product change may be incorporated with or without prior notice and without 
ligation to Fiat-Allis or its affiliates. 



pi 

FIAT-ALUS 



SUPPLEMENT NO. 3 

FUEL INJECTION PUMP 

(ROOSA-MASTER DM SERIES) 

SERVICE MANUAL AND PARTS CATALOG 

FORM 73112988 



( 

( 6-79 )/ 



ATTENTION: Insert this sheet in the front of publication as record of receipt. Replace or add pages 
in the publication according to instructions below. 

Additional copies of this supplement are available. Please direct your request to: 
Fiat-Allis Construction Machinery, Inc., Publications Services Dept, 
3000 South 6th Street, Springfield, Illinois 62710 U.S.A. 

or 
Fiat-Allis M.M.T. S.p.A. - MAGAZZINO STAMPATI - Viale Torino,, 
STUPINIGI (Torino) - Italy 



Replace the following like pages: 



9-1 
9-2 

9-3 

94 

9-5 
9-6 



(Revised) 
(No change) 

(No change) 
(Revised) 

(Revised) 
(Revised) 



12-7 (Revised) 
12-8 (Nocha* ^ 



9-7 (Added) 
BLANK 



Reason: Add Service Manual data for new^ries engines. 




12-33 (Revised) 

12-34 (Added) 

12-35 (Added) 

12-36 (Added) 

12-37 (Added) 

12-38 (Added) 



c 



Any/product change described in this publication is part of the continuing effort of Fiat-Allis to make its product responsive to customer 
nqrfd and is not to be construed as a field campaign. A product change may be incorporated with or without prior notice and without 
ligation to Fiat-Allis or its affiliates. 



c 



pi 

FIAT-ALUS 



SUPPLEMENT NO. 2 

FUEL INJECTION PUMP 

(ROOSA-MASTER DM SERIES) 

SERVICE MANUAL AND PARTS CATALOG 

FORM 73112988 



c 



( 3-79 ) 
ATTENTION: Insert this sheet in the front of publication as record of receipt. Replace or add pages, 
in the publication according to instructions below. 

Additional copies of this supplement are available. Please direct your request to: 
Fiat-Allis Construction Machinery, Inc., Publications Services Dept, 
3000 South 6th Street, Springfield, Illinois 62710 U. S. A. 



Write in the following changes: 



Page 9-6 

Timing B.T.D.C. 

Page 12-13 



16 Static 



14 
J^ Static 



3500 



14 



Static 



USAGE: 645-B Wheel Loader (ModeliseCgMKIJ / £ *? 



•<. 



# o- 



'V, 



.V 



c 



Anyyproduct change described in this publication is part of the continuing effort of Fiat-Allis to make its product responsive to customer need 
■is not to be construed as a field campaign. A product change may be incorporated with or without prior notice and without obligation to 
t-AHis or its affiliates,. 



FIAT-ALUS 



SUPPLEMENT NO. 1 

FUEL INJECTION PUMP 

(ROOSA-MASTER DM SERIES) 

SERVICE MANUAL AND PARTS CATALOG 

FORM 73112988 



( 1-79) 
ATTENTION: Insert this sheet in the front of publication as record of receipt. Replace or add pages 
in the publication according to instructions below. 

Additional copies of this supplement are available. Please direct your request to: 
Fiat-Allis Construction Machinery, Inc., Publications Services Dept, 
3000 South 6th Street, Springfield, Illinois 62710 U. S. A. 



Replace the following pages: 

V (Revised) 

VI (No change) 

8-1 (Revised) 
8-2 (Revised) 

8-3 (Revised) 
8-4 (Revised) 

8-5 (Added) 
Blank 

9-1 (Revised) 
9-2 (Revised) 

9-3 (Revised) 
9-4 (Revised) 

9-5 (Added) 
9-6 (Added) 



12-3 (Revised) 
12-4 (Revised) 



12-5 (Rev ; y 
12-6 (Rr 






*> 



** ^ 



^ ^/ised) 
evised) 

i (Added) 
<£/l2 (Added) 

12-13 (Added) 
12-14 (Added) 

12-15 (Added) 
12-16 (Added) 

12-17 (Added) 
12-18 (Added) 



12-19 (Added) 
12-20 (Added) 

12-21 (Added) 
12-22 (Added) 

12-23 (Added) 
12-24 (Added) 

12-25 (Added) 
12-26 (Added) 

12-27 (Added) 
12-28 (Added) 

12-29 (Added) 
12-30 (Added) 

12-31 (Added) 
12-32 (Added) 

12-33 (Added) 
Blank 



c 



Reason: To provide complete fuel injection pump service, calibration and 
parts/information, for the "DM" series pump as applicable to the 
262/B, 263-B Scrapers, 545-B, 605-B, 645-B and 745-C Wheel 
loaders and the 100-C, 150-C and 200-C Graders. 



Any ifroduct change described in this publication is part of the continuing effort of Fiat-Allis to make its product responsive to customer need / 
ancKis not to be construed as a field campaign. A product change may be incorporated with or without prior notice and without obligation to V 



fat-Aliis or its affiliates. 



c 



c 



SAFETY 

GENERAL 

Study the Operation and Maintenance Instruction Manual be- 
fore starting, operating, maintaining, fueling, or servicing 
machine. 

Read and heed all machine-mounted safety signs before 
starting, operating, maintaining, fueling or servicing machine. 

Machine-mounted safety signs have been color coded yellow 
with black border and lettering for WARNING and red with 
white border and lettering for DANGER points. 

Never attempt to operate the machine or its tools from any 
position other than seated in the operator's seat. Keep head, 
body, limbs, hands and feet inside operator's compartment at 
all times to reduce exposure to hazards outside the operator's 
compartment. 

Do not allow unauthorized personnel to operate service or 
maintain this machine. 

Always check work area for dangerous features. The follow- 
ing are examples of dangerous work areas: slopes, over 
hangs, timber, demolitions, fire, high walls, dropoff, backfills, 
rough terrain, ditches, ridges, excavations, heavy traffic, 
crowded parking, crowded maintenance and closed areas. 
Use extreme care when in areas such as these. 

An operator must know the machine's capabilities. When 
working on slopes or near drop offs be alert to avoid loose or 
soft conditions that could cause sudden tipping or loss of 
control. 

Do not jump on or off machine. Keep two hands and one foot, 
or two feet and one hand, in contact with steps grab rails and 
handles at all times. 



RULES 

Do not wear rings, wrist watches, jewelry, loose or hanging 
apparel, such as ties, torn clothing, scarves, unbuttoned or 
unzipped jackets that can catch on moving parts. Wear proper 
safety equipment as authorized for the job. Examples: hard 
hats, safety shoes, heavy gloves, ear protectors, safety 
glasses or goggles, reflector vests, or respirators. Consult 
your employer for specific safety equipment requirements. 

Do not carry loose objects in pockets that might fall unnoticed 
into open compartments. Do not use machine to carry loose 
objects by means other than attachments for carrying such 
objects. 

DO NOT CARRY RIDERSun\essthe machine is equippedfor 
carrying people to reduce personal exposure to being thrown 
off. 

Do not operate machinery in a condition of extreme fatigue 
or illness. Be especially careful towards the end of the shift. 

Roll Over Protective Structures are required on wheel load- 
ers, dozer tractors, track type loaders, graders and scrapers 
by local or national requirements. DO NOT operate this 
machine without a Roll Over Protective Structure. 

Do not operate a machine without a falling object protective 
structure (FOPS). 

Do not operate this machine without a rear canopy screen 
when machine is equipped with rear mounted towing winch. 

Seat belts are required to be provided with roll over protective 
structures or roll protection cabs by local or national regula- 
tions. Keep the safety belt fastened around you during opera- 
tion. 



c 



Do not use controls or hoses as hand holds when climbing on 
or off machine. Hoses and controls are movable and do not 
provide a solid support. Controls also may be inadvertently 
moved causing accidental machine or equipment movement. 

Keep operator's compartment, stepping points, grab-rails 
and handles clear of foreign objects, oil, grease, mud or snow 
accumulation to minimize the danger of slipping or stumbling. 
Clean mud or grease from shoes before attempting to mount 
or operate the machine. 

Be careful of slippery conditions on stepping points, hand 
rails, and on the ground. Wear safety boots or shoes that have 
a high slip resistant sole material. 

For your personal protection. Do not attempt to climb on or off 
machine while machine is in motion. 

Never leave the machine unattended with the engine running. 

Always lock up machine when leaving it unattended. Return 
keys to authorized security. Heed all shut down procedures of 
the Operation and Maintenance Instruction Manual. Always 
set the parking brake when leaving the machine for any 
reason. 



Where noise exposure exceeds 90 dBA for 8 hours, wear 
authorized ear protective equipment per local or national 
requirements that apply. 

Keep clutches and brakes on machine and attachments such 
as power control units, winches and master clutches adjusted 
according to Operation and Maintenance Instruction Manuals 
of the manufacturers at all times. DO NOT adjust machine 
with engine running except as specified. 

Do not operate a machine with brakes out of adjustment. See 
the Operation and Maintenance Instruction Manual. 

Move carefully when under, in or near machine or imple- 
ments. Wear required protective equipment, such as hard 
hat, safety glasses, safety shoes, ear protectors. 

To move a disabled machine, use a trailer or low boy truck if 
available. If towing is necessary, provide warning signals as 
required by local rules and regulations and follow Operation 
and Maintenance Instruction Manual recommendations. Load 
and unload on a level area that gives full support to the trailer 
wheels. Use ramps of adequate strength, low angle and 
proper height. Keep trailer bed clean of clay, oil and all mate- 
rials that become slippery. Tie machine down securely to 
truck or trailer bed and block tracks (or wheels) as required by 
the carrier. 



SAFETY RULES 



To prevent entrapment in cabs or mounted encbsures, 
observe and know the mechanics of alternate exit routes. 

On machines equipped with suction radiator fans, be sure to 
periodically check all engine exhaust parts for leaks as 
exhaust gases are dangerous to the operator. Keep a vent 
open to outside air at all times when operating within a closed 
cab. 

STARTING FLUID IS FLAMMABLE. Follow the recommen- 
dations as outlined in the Operation and Maintenance Instruc- 
tion Manual and as marked on the containers. Store contain- 
ers in cool, well-ventilated place secure from unauthorized 
personnel. DO NOT PUNCTURE OR BURN CONTAINERS. 

Followthe recommendations of the manufacturer for storage 
and disposal. 

Wire rope develops steel slivers. Use authorized protective 
equipment such as heavy gloves, safety glasses when han- 
dling. 

OPERATION 



Use recommended bucket for machine and material load 
ability and heaping characteristics of material, terrain, and 
other pertinent job conditions. 

Avoid abrupt starts and stops when transporting a loaded 
bucket. 

Inspect your seat belt webbing and hardware at least twice a 
year for signs of fraying, wear or other weakness that could 
lead to failure. 

Use only designated towing or pulling attachment points. Use 
care in making attachment. Be sure pins and locks as pro- 
vided are secure before pulling. Stay clear of draw bars, 
cables or chains under load. 

When pulling or towing through a cable or chain, do not start 
suddenly at full throttle. Take up slack carefully. Guard 
against kinking chains or cables. Inspect carefully for flaws 
before using. Do not pull through a kinked chain or cable due 
to the high stresses and possibility of failure of the kinked 
area. Always wear heavy gloves when handling chain or 
cable. 



c 



Before starting machine, check, adjust and lock the operator's 
seat for maximum comfort and control of the machine. 

DO NOT START OR OPERATE AN UNSAFE MACHINE. 
Before working the machine, be sure that any unsafe condi- 
tion has been satisfactorily remedied. Check brakes, steering 
and attachment controls before moving. Advise the proper 
maintenance authority of any malfunctioning part or system. 
Be sure all protective guards or panels are in place, and all 
safety devices provided are in place and in good operating 
condition. 

Check instruments at start-up and frequently during opera- 
tion. 



Be sure cables are anchored and the anchor point is strong 
enough to handle the expected load. Keep exposed person- 
nel clear of anchor point and cable or chain. DO NOT PULL 
OR TOW UNLESS OPERATOR'S COMPARTMENT OF 
MACHINES INVOLVED ARE PROPERLY GUARDED 
AGAINST POTENTIAL CABLE OR CHAIN BACKLASH. 

During operation always carry ripper in full raised position 
when not in use and lowered to ground when parked. 

When counterweights have been provided, do not work 
machine if they have been removed unless their equivalent 
weight has been replaced. See the Operation and Mainte- 
nance Instruction Manual. 



c 



Do not run the engine of this machine in closed areas without 
proper ventilation to remove deadly exhaust gases. 

Be sure exposed personnel in the area of operation are clear 
of the machine before moving the machine or its attachments. 
WALK COMPLETELY AROUNDXhe machine before mount- 
ing. Sound horn. Obey flag man, safety signals and signs. 

Knowthe principles of cross steering of crawlertractors. Read 
section in Operation and Maintenance Instruction Manual on 
cross steering. 

Keep engine exhaust system and exhaust manifolds clear of 
combustible material. Equip machine with screens and guards 
when working under conditions of flying combustible material. 

If engine has a tendency to stall for any reason under load or 
idle, report this for adjustment to a proper maintenance 
authority immediately. Do not continue to operate machine 
until condition has been corrected. 

Never use bucket as a man-lift. 



When operating a machine know what clearances will be 
encountered, overhead doors, wires, pipes, aisles, road- 
ways; also the weight limitations of ground, floor, and ramps. 

Know bridge and culvert load limits and do not exceed them. 
Know machine's height, width, and weight. Use a signal 
person when clearance is close. 

Be sure that the exact location of gas lines, utility lines, 
sewers, overhead and buried power lines, and other obstruc- 
tions or hazards are known. Such locations should be pre- 
cisely marked by the proper authorities to reduce the risk of 
accidents. Obtain shut-down or relocation of any such facili- 
ties before starting work, if necessary. 

Be certain to comply with all local, state, and federal regula- 
tions regarding working in the vicinity of power lines. 

When reading find out what conditions are likely to be met - 
clearances, congestion, type of surface, etc. Be aware of fog, 
smoke or dust element that obscure visibility. 

When backing, always look to where the machine is to be 
moved. Be alert to the position of exposed personnel. DO 
NOT OPERATE if exposed personnel enter the immediate 
work area. 



c 



SAFETY RULES 



( 



c 



c 



Never travel a machine on a job she, in a congested area, or 
around people without a signal person to guide the operator. 

In darkness, check area of operation carefully before moving 
in with machine. Use all lights provided. Do not move into area 
of restricted visibility. 

Maintain clear vision of all areas of travel or work. Keep cab 
windows dean and repaired. Carry blade low for maximum 
visibility while traveling. Obtain and use fan blast deflectors 
where tractors are used a pusher tractors in tandem. 

Transport a loaded bucket with the bucket as far tipped back 
and in as low a position as possible for maximum visibility, 
stability, and safest transport of the machine. Carry it at a 
proper speed for the load and ground conditions. 

Carry the bucket low when traveling with a load. 

Maintain a safe distance from other machines. Provide suffi- 
cient clearance for ground and visibility conditions. Yield 
right-of-way to loaded machines. 

Avoid going over obstacles such as rough terrain, rocks, logs, 
curbs, ditches ridges, and railroad tracks whenever possible. 
When obstructions must be crossed, do so with extreme care 
at an angle if possible. Reduce speed - down-shift. Ease up 
to the break over point - pass the balance point slowly on the 
obstruction and ease down on the other side. 

Cross gullies or ditches at an angle with reduced speed after 
insuring ground conditions will permit a safe traverse. 

Be alert to soft ground conditions close to newly constructed 
walls. The fill material and weight of machine may cause the 
wall to collapse under the machine. 

Operate at speeds slow enough to insure complete control at 
all times. Travel slowly over rough ground, on slopes or near 
drop offs, in congested areas or on ice or slippery surfaces. 

Be alert to avoid changes in traction conditions that could 
cause loss of control. DO NOTdr'we on ice or frozen ground 
conditions when working the machine on steep slopes or near 
drop offs. 

Keep the machine well back from the edge of an excavation. 

Be especially careful when traveling up or down slopes. 
Position the bucket in such a way as to provide a possible 
anchorage on the ground in case of a slide. 

When proceeding across a hill side proceed slowly. Never 
turn sharply up hill or down hill. 

Avoid side hill travel whenever possible. Drive up and down 
the slope. Should the machine start slipping sideways on a 
grade, turn it immediately downhill. 

In steep down hill operation, do not allow engine to over 
speed. Select proper gear before starting down grade. 

There is no substitute for good judgement when working on 
slopes. 



The grade of slope you should attempt will be limited by such 
factors as condition of the ground, load being handled, the 
type of machine, speed of machine and visibility. 

NEVER COASTXhe machine down grades and slopes with 
the transmission in neutral on power shift machines, or clutch 
disengaged on manually shifted machines. 

To reduce the danger of uncontrolled machine, chooseagear 
speed before proceeding down grade that will hold machine 
to proper speeds for conditions. 

Operating in virgin rough terrain that includes previously 
mentioned hazards is called pioneering. Be sure you know 
how this is done. Danger from falling branches and upturning 
roots is acute in these areas. 

When pushing overtrees,the machine must be equipped with 
properoverheadguarding. Never allow a machine to climb up 
on the root structure particularly while the tree is being felled. 
Use extreme care when pushing over any tree with dead 
branches. 

Avoid brush piles, logs or rocks. DO NOT DRIVE THE 
MACHINE ONTO BRUSH PILES, LOGS, LARGE ROCKSor 
other surface irregularities that break traction with the ground 
especially when on slopes or near drop offs. 

Avoid operating equipment too close to an over hang or high 
wall either above or below the machine. Be on the look out for 
caving edges, falling objects and slides.Beware of conceal- 
ment by brush and under growth of these dangers. 

Park in a non-operating and non-traffic area or as instructed. 
Park on firm level ground if possible. Where not possible, 
position machine at a right angle to the slope, making sure 
there is no danger of uncontrolled sliding movement. Set the 
parking brake. 

Never park on an incline without carefully blocking the ma- 
chine to prevent movement 

If parking in traffic lanes cannot be avoided, provide appropri- 
ate flags, barriers, flares and warning signals as required. 
Also provide advance warning signals in the traffic lane of 
approaching traffic. 

Move the machine away from pits, trenches, overhangs and 
over head power lines before shutting down for the day. 

When stopping operation of the machine for any reason, 
always return the transmission or hydrostatic drive control to 
neutral and engage the control lock to secure the machine for 
a safe start up. Set parking brake, if so equipped. 

Never lower attachments ortoolsfrom any position otherthan 
seated in operator's seat. Sound the horn. Make sure the area 
near the attachment is clear. Lower the attachment slowly. 
DO NOT USE float position to lower hydraulic equipment. 



Ill 



SAFETY RULES 



Always before leaving the operator's seat and after making 
certain all people are clear of the machine, slowly lower the 
attachments or tools flat to the ground in a positive ground 
support position. Move any multi purpose tool to positive 
closed position. Return the controls to hold. Place transmis- 
sion control in neutral and move engine controls to off 
position. Engage all control locks, set parking brake, and 
open and lock the master (key, 'rf so equipped) switch. Consult 
Operation and Maintenance Instruction Manual. 

Always follow the shut down instructions as outlined in the 
Operation and Maintenance Instruction Manual. 

MAINTENANCE 

Do not perform any work on equipment that is not authorized. 
Follow the Maintenance or Service Manual procedures. 

Machine should not be serviced with anyone in the operator's 
seat unless they are qualified to operate the machine and are 
assisting in the servicing. 

Shut off engine and disengage the Power Take Off lever 'rf so 
equipped before attempting adjustments or service. 

Always turn the master switch (key switch if so equipped) to 
the OFF position before cleaning, repairing, orservicing and 
when parking machine to forestall unintended or unauthor- 
ized starting. 

Disconnect batteries and TAG all controls according to local 
or national requirements to warn that work is in progress. 
Block the machine and all attachments that must be raised 
per local or national requirements. 

Never lubricate, service or adjust a machine with the engine 
running, except as called for in the Operation and Mainte- 
nance Instruction Manual. Do not wear loose clothing or 
jewelry near moving parts. 

Do not run engine when refueling and use care if engine is hot 
due to the increased possibility of a fire if fuel is spilled. 

Do not smoke or permit any open flame or spark near when 
refueling, or handling highly flammable materials. 

Always place the fuel nozzle against the side of the filler 
opening before starting and during fuel flow. To reduce the 
chance of a static electricity spark, keep contact until after fuel 
flow is shut off. 

Do not adjust engine fuel pump when the machine is in 
motion. 

Never attempt to check or adjust fan belts when engine is 
running. 

When making equipment cheeks that require running of the 
engine, have an operator in the operator's seat at all times 
with the mechanic in sight. Place the transmission in neutral 
and set the brakes and lock. KEEP HANDS AND CLOTHING 
AWAY FROM MOVING PARTS. 



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Avoid running engine with open unprotected air inlets. If such 
running is unavoidable for service reasons, place protective 
screens over all inlet openings before servicing engine. 

Do not place head, body, limbs, feet, fingers, or hands near 
rotating fan or belts. Be especially alert around a pusher fan. 

Keep head, body, limbs, feet, fingers, or hands away from 
bucket, blade or ripper when in raised position. 

If movement of an attachment by means of machine's hydrau- 
lic system or winches is required for service or maintenance, 
do not raise or lower attachments from any position otherthan 
when seated in the operator's seat. Before starting machine 
or moving attachments or tools, set brakes, sound horn and 
call for an all clear. Raise attachments slowly. 

Never place head, body, limbs, feet, fingers, or hands into an 
exposed portion between uncontrolled or unguarded scissor 
points of machine without first providing secure blocking. 

Never align holes with fingers or hands - Use the proper 
aligning tool. 



Disconnect batteries before working on electrical system or 
repair work of any kind. 

Check for fuel or battery electrolyte leaks before starting 
service or maintenance work. Eliminate leaks before pro- 
ceeding. 

BATTERYGAS IS HIGHLY FLAMMABLE Leave battery box f 
open to improve ventilation when charging batteries. Never v__ 
check charge by placing metal objects across the posts. Keep 
sparks or open flame away from batteries. Do not smoke near 
battery to guard against the possibility of an accidental 
explosion. 

Do not charge batteries in a closed area. Provide proper 
ventilation to guard against an accidental explosion from an 
accumulation of explosive gases given off in the charging 
process. 

Be sure to connect the booster cables to the properterminals 
(+to+) and (-to-) at both ends. Avoid shorting clamps. Follow 
the Operation and Maintenance Instruction Manual proce- 
dure. 

Due tothe presence of flammable fluid, never check orf ill fuel 
tanks, storage batteries or use starter fluid near lighted 
smoking materials or open flame or sparks. 

Rust inhibitors are volatile and flammable. Prepare parts in 
well ventilated place. Keep open flame away - DO NOT 
SMOKE. Store containers in a cool well ventilated place 
secured against unauthorized personnel. 

Do not use an open flame as a light source to look for leaks 
or for inspection anywhere on the machine. 

DO NOTpWe oily or greasy rags - they are a fire hazard. Store ^- 
in a closed metal container. 



IV 



SAFETY RULES 



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Never use gasoline or solvent or other flammable fluid to 
clean parts. Use authorized commercial, non-flammable, 
non-toxic solvents. 

Never place gasoline or diesel fuel in an open pan. 

Shut off engine and be sure all pressure in system has been 
relieved before removing panels, housings, covers, and caps. 
See Operation and Maintenance Instruction Manual. 

Do not remove hoses or check valves in the hydraulic system 
without first removing load and relieving pressure on the 
supporting cylinders. Turn radiator cap slowly to relieve 
pressure before removing. Add coolant only with engine 
stopped or idling if hot. See Operation and Maintenance 
Instruction Manual. 

Fluid escaping under pressure from a very small hole can 
almost be invisible and can have sufficient force to penetrate 
the skin. Use a piece of card board or wood to search for 
suspected pressure leaks. DO NOT USE HANDS. If injured 
by escaping fluid, see a doctor at once. Serious infection or 
reaction can develop if proper medical treatment is not 
administered immediately. 

Never use any gas other than dry nitrogen to charge accumu- 
lators. See Operation and Maintenance Instruction Manual. 

When making pressure checks use the correct gauge for 
expected pressure. See the Operation and Maintenance 
Instruction Manual or Service Manual for guidance. 

For field service, move machine to level ground if possible 
and block machine. If work is absolutely necessary on an 
incline, block machine and its attachments securely. Move 
the machine to level ground as soon as possible. 

Brakes are inoperative when manually released forservicing. 
Provision must be made to maintain control of the machine by 
blocking or other means. 

Block all wheels before bleeding or disconnecting any brake 
system lines and cylinders. 

Never use make shift jacks when adjusting track tension. 
Follow the Undercarriage Service Manual. 

Know your jacking equipment and its capacity. Be sure the 
jacking point used on the machine is appropriate for the load 
to be applied. Be sure the support of the jack at the machine 
and under the jack is appropriate and stable. Any equipment 
up on a jack is dangerous. Transfer load to appropriate 
blocking as a safety measure before proceeding with service 
or maintenance work according to local or national require- 
ments. 

Always block with external support any linkage or part on 
machine that requires work under the raised linkage, parts, or 
machine per local or national requirements. Never allow 
anyone to walk under or be near unblocked raised equipment. 
Avoid working or walking under raised blocked equipment 
unless you are assured of your safety. 



When servicing or maintenance requires access to areasthat 
cannot be reached from the ground, use a ladder or step 
platform that meets local or national requirements to reach 
the service point. If such ladders or platforms are not avail- 
able, use the machine hand holds and steps as provided. 
Perform all service or maintenance carefully. 

Shop or field service platforms and ladders used to maintain 
or service machinery should be constructed and maintained 
according to local or national requirements. 

Lift and handle all heavy parts with a lifting device of proper 
capacity. Be sure parts are supported by proper slings and 
hooks. Use lifting eyes if provided. Watch outfor people in the 
vicinity. 

In lifting and handling heavy parts, slings must be of adequate 
strength for the purpose intended and must be in good 
condition. 

Handle all parts with extreme care. Keep hands and fingers 
from between parts. Wear authorized protective equipment 
such as safety glasses, heavy gloves, safety shoes. 

When using compressed air for cleaning parts use safety 
glasses with side shields or goggles. Limit the pressure to 207 
kPa (30 psi) according to local or national requirements. 

Wear welders protective equipment such as dark safety 
glasses, helmets, protective clothing, gloves and safety shoes 
when welding or burning. Wear dark safety glasses near 
welding. DO NOT LOOK AT ARC WITHOUT PROPER EYE 
PROTECTION 

Replace seat belts every two years on open canopy units and 
every three years on machines With cabs or at change of 
ownership. 

Wear proper protective equipment such as safety goggles or 
safety glasses with side shields, hard hat, safety shoes, 
heavy gloves when metal or other particles are apt to fly or fall. 

Use only grounded auxiliary powersource for heaters, charg- 
ers, pumps and similar equipment to reduce the hazards of 
electrical shock. 

Keep maintenance area CLEAN and DRY. Remove water or 
oil slicks immediately. 

Remove sharp edges and burrs from reworked parts. 

Be sure all mechanics tools are in good condition. DO NOT 
use tools with mushroomed heads. Always wear safety 
glasses with side shields. 

Do not strike hardened steel parts with anything other than a 
soft iron or non-ferrous hammer. 

Do not rush. Walk, do not run. 

Know and use the hand signals used on particular jobs and 
know who has the responsibility for signaling. 



SAFETY RULES 



Face the access system when climbing up and down. 

Apply the parking device and place the transmission in neutral 
before starting the machine. 

Do not bypass the starter safety switch. Repair the starter 
safety controls if they malfunction. 

Fasten seat belt before operating. 

Steering should be checked to both right and left. Brakes 
should be tested against engine power. Clutch and transmis- 
sion controls should be moved through or to neutral positions 
to assure disengagement. Operate all controls to insure 
proper operation. If any malfunctions are found, park ma- 
chine, shut off engine, report and repair before using ma- 
chine. 

If the power steering or the engine ceases operating, stop the 
machine motion as quickly as possible. Lower equipment, set 
parking device and keep machine securely parked until the 
malfunction is corrected or the machine can be safety towed. 
Never lift loads in excess of capacity. 

Should the machine become stuck or frozen to the ground, 
back out to avoid roll over. 

Know and understand the job site traffic flow patterns. 

Keep the machine in the same gear going down hill as used 
for going up hill. 

When roading a machine, know and usethe signaling devices 
required on the machine. Provide an escort for roading where 
required. 

Always use the recommended transport devices when road- 
ing the machine. 

Do not attempt repairs unless proper training has been 
provided. 



Use extreme caution when removing radiator caps, drain 
plugs, grease fittings or pressure taps. Park the machine and 
let it cool down before opening a pressurized compartment. 

Release all pressure before working on systems which have 
an accumulator. 

When necessary to tow the machine, do not exceed the 
recommended towing speed, be sure the towing machine has 
sufficient braking capacity to stop the towed load. If the towed 
machine cannot be braked, a tow bar must be used or two 
towing machines must be used - one in front pulling and one 
in the rear to retard. Avoid towing over long distances. 

Observe proper maintenance and repair of all pivot pins, 
hydraulic cylinders, hoses, snap rings and main attaching 
bolts. 

Always keep the brakes and steering systems in good oper- 
ating condition. 

Replace all missing, illegible or damaged safety signs. Keep 
all safety signs clean. 

Do not fill the fuel tank to capacity. Allow room for expansion. 

Wipe up spilled fuel immediately. 

Always tighten the fuel tank cap securely. Should the fuel cap 
be lost, replace it only with the original manufacturers ap- 
proved cap. Use of a non-approved cap may result in over- 
pressurization of the tank. 

Never drive the machine near open fires. 

Use the correct fuel grade for the operating season. 



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VI 



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FOREWORD 



Always furnish serial number if making an inquiry to dealer orfactory 
about this machine. 

Many equipment owners employ the Dealer Service Department for 
all work other than routine lubrication and minor service. This 
practice is encouraged, as our Dealers are well informed and 
equipped to render efficient service by factory trained mechanics. 

This manual may not be reprinted or reproduced, either in whole or 
in part, without written permission of Fiatallis ®. 

Illustrations show standard and optional items. 



IMPORTANT 



The information in this manual was current at the time of publication. 
It is our policy to constantly improve our product and to make 
available additional items. These changes may affect procedures 
outlined in this manual. If variances are observed, verify the informa- 
tion through your Dealer. 

Fiatallis is not responsible for any liability arising from any damage 
resulting from defects caused by parts and/or components not 
approved by Fiatallis for use in maintaining and/or repairing products 
manufactured or merchandized by Fiatallis. 

In any case, no warranty of any kind is made or shall be imposed with 
respectto products manufactured or merchandized by Fiatallis when 
failures are caused by the use of parts and/or components not ap- 
proved by Fiatallis. 



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TABLE OF CONTENTS 



TOPIC 



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10 

11 



12 



TITLE PAGE 

Safety Rules I 

General 0-2 

A. Purpose of the Manual 0-2 

B. Model Number System 0-2 

C. General Information 0-2 

Construction and Operation 1-1 

A. Components and Functions 1-1 

B. Fuel Flow - - 1-2 

C. Transfer Pump - - - 1-3 

D. Charging and Discharging 1-5 

E. Delivery Valve Function 1-6 

F. Return Oil Circuit 1-7 

G. Mechanical Governor 1-7 

H. Automatic Advance 1-8 

Removal From Engine 2-1 

Disassembly 3-1 

Parts Inspection 4-1 

A. General Inspection 4-1 

B. Detailed Inspection 4-1 

C. Supplementary Inspection 4-2 

Reassembly 5-1 

Accessories 6-1 

Electrical Shut- Off - 6-1 

Speed Light Load Advance 6-4 

Aneroid 6-6 

Torque Control 7-1 

Spill Port/Torque Chopper - - - 7-2 

Test Bench Data 8-1 

A. Bench Component and Test Fluid 

Recommendations 8-1 

B. Checking Bench Drive Shaft Alignment 8-4 

Fluid Injection Pump References, Calibration 

Procedures and Data 9-1 

A. References • 9-1 

B. Calibration Procedures 9-1 

C. Procedure Example 9-3 

D. Aneroid Adjustments 9-3 

E. Calibration Data 9-4, 5, 6 

Installation (Fuel Injection Pump) 10-1 

General Data 11-1 

Service Tools 11-1 

Torque Values 11-3 

Troubleshooting 1 1-4 

Parts Catalog (Roosa-Master Pumps) 

262-B, 263-B Scrapers 12-2 

545-B, 605-B Wheel Loaders 12-6 

645-B Wheel Loaders - - - 12-12, li 

745-C Wheel Loaders - 12-24 

100-C, 150-C, 200-C Graders 12-30 



NOTICE 



CONSULT FIAT-ALLIS DEALER FOR OTHER 
SERVICE MANUALS AVAILABLE FOR YOUR 
UNIT. SEE TECHNICAL PUBLICATIONS INDEX 
70658800 FOR ALL AVAILABLE PUBLICATIONS. 



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Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 
SERVICE MANUAL 
FORM 73112988 



0-1 



(Revised January 1979) 



GENERAL 



A.PURPOSE OF THE MANUAL 

This manual is expressly intended to pro- 
vide sufficient information for qualified 
technicians, experienced in diesel engines 
and diesel injection equipment, to disas- 
semble and reassemble the Roosa Master 
DM Type Fuel Injection Pump and to make 
such adjustments and parts replacements as 
may be needed. It is recommended that an 
inexperienced person refrain from making 
adjustments and repairs, as such action 
may result in very extensive damage to the 
pump and possibly to the engine . 

No service should be performed on the pump 
before making a careful study of this manual 
and becoming familiar with the principles 
and instructions which follow . Since several 
critical adjustments of the injection pump 
are required which cannot readily be made 
on the engine, it is also necessary that the 
service be performed in a facility equipped 
with the proper special tools and an approved, 
motorized test stand. 

This manual completely describes the • 
operating principles of the pump and most 
accessories . Only through a thorough 
knowledge of these principles can the service- 
man locate and correct possible operational 
defects . 

B. MODEL NUMBER SYSTEM 

It is necessary to understand the model 
number system for reference to the proper 
sections of this manual covering operation 
and maintenance of the pump . 

EXAMPLE: Model Number 

a b_ c. _d _e f_ 

DM 2 6 33 JN 2580 

a. DM - "M" version of "D" series pump. 

b . 2 - Number of Plungers (2 or 4 plunger 
versions) . 

c. 6 - Number of Cylinders (available in 2, 
3.4.6 and 8 cylinder configuration). 



d. 3& -* Abbreviation of Plunger Diameter. 
25- .250" (6.35mm) 33- .330" (8.38mm) 
27 - .270" (6.86mm) 35 - .350" (8.89mm) 
29- .290" (7.37mm) 37- .370" (9.40mm) 
31- .310" (7.87mm) 39- .390" (9.91mm) 

e . JN - Accessory Code . 

The code pertains to combinations of 
special accessories such as electrical 
shut-off, automatic advance, variable 
speed droop adjustment, etc. See the 
proper manual section for operation and 
construction of these accessories. In- 
clude this in any reference to the pump . 

f . 2580 - Specification Number. 
Determines selection of parts and adjust- 
ments within a given accessory code . 
Must be included in any reference to the 
pump. 



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C. GENERAL INFORMATION 

In a diesel engine, air is drawn into the 
cylinder through the intake valve and com- 
pressed. A metered quantity of fuel is then 
injected into the cylinder, producing a com- 
bustible misture . This mixture ignites from 
heat of compression, and the expanding 
gases force the piston downward. 

The function of a diesel fuel injection pump 
is to accurately meter and deliver fuel to a 
nozzle in each cylinder and to inject it at 
high pressure into the combustion chamber 
at precisely timed intervals . The extreme 
precision necessary can well be appreciated 
since this cycle must be repeated thousands 
of times per minute with virtually no varia- 
tion in timing or amount of fuel injected . 

MODEL DM PUMP 

The models DM2 and DM4 are described as 
opposed plunger, inlet metering, distributor 
type pumps. The DM2 incorporates a single 
pumping chamber, whereas the DM4 has 2 
pumping chambers . 



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General 

The necessity for cost reduction is more 
apparent in the small diesel engine where 
the injection equipment represents a greater 
percentage of the cost . Since the basic 
model has but 100 odd parts, and only four 
main rotating members, there is less chance 
of part failure . Repairs are generally very 
inexpensive. Today's small high output 
engines have created a need for improved, 2 * 

yet low cost injection equipment capable of 
higher speed operation, quieter running and 
lower exhaust emissions . 

Precise distribution. between cylinders, in- 3 * 

herent in the pump design, and the ability to 
preset fuel flow eliminates lengthy periods 
on the test stand. The pump is self lubri- 
cated (with the exception of the drive shaft 
ball bearing), contains essentially the same 
number of parts regardless of the number 
of cylinders served, and operates in any 
position . 



NEW DESIGN FEATURES 

This addition to the line of fuel injection 
equipment incorporates many design 
improvements, and has been durability 
tested for more than 200,000 hours prior to 
release for production. 

New Design Features include: 

1 . Housing and Drive 

A . Housing strengthened in the neck 
area. 

B . Rugged mounting flange . 

C „ Drive shaft supported by a heavy 
duty ball bearing. 



D. Increased diameter drive shaft with 
larger tang drive . The drive shaft 
is retained in the pump . 

E . Drive shaft roll pin for gear hub 
alignment . 

F. Spring-loaded, steel-backed, lip 
type drive shaft seals. 

Head and Rotor 

A . Integral, angled discharge fittings 

B . Threaded transfer pump cap . 

C . Shear groove in the rotor . 

Governor 

A . Weight retainer hub press fitted to 
the rotor. 

B . Cushioned weight retainer with 
rubber compression members fully 
enclosed within the assembly . 

C . Low mass governor weights . 

D. Larger diameter metering valve. 

Transfer Pump 

A. Larger area inlet screen. 



5 . Automatic Advance 

A . Advance circuit direct from transfer 
pump. 

B . Reed check valve . 



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Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

0-3 



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TOPIC 1 CONSTRUCTION AND OPERATION 



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■FIG. 1.1 



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A. COMPONENTS AND FUNCTIONS 

It is necessary to become familiar with the 
function of the main components to under- 
stand the basic operating principles of the 
DM pump . See cutaway view (Fig .1.1) for 
construction details . 

MAIN COMPONENTS 

1 . Drive Shaft 

2 . Distributor Rotor 

3 . Transfer Pump Blades 

4. Pumping Plungers 

5 . Internal Cam Ring 

6. Hydraulic Head 

7. Pressure Regulator Assembly 

8. Governor 

9. Automatic Advance 

10. Housing 

11. Metering Valve 



The main rotating components are the drive 
shaft (1), distributor rotor (2), transfer 
pump blades (3), governor (8). 

With reference to Fig. 1.1, the drive en- 
gages the distributor rotor in the hydraulic 
head . The drive end of the DM2 rotor in- 
corporates two pumping plungers and the 
DM4 incorporates four . 

The plungers are actuated toward each 
other simultaneously by an internal cam 
ring through rollers and shoes which are 
carried in slots at the drive end of the rotor 
The number of cam lobes normally equals 
the number of engine cylinders . 

The transfer pump at the rear of the rotor 
is of the positive displacement vane type 
and is enclosed in the end cap. The end cap 
also houses the fuel inlet strainer and 
transfer pump pressure regulator. The 



Study SAFETY RULES, pages I thru III. thoroughly for the protection of personal and machine safety. 

1-1 



Construction and Operation 



D INLET 

□ TRANSFER PUMP PRESSURE 

□ HOUSING PRESSURE 
■ INJECTION LINE PRESSURE 

LUBE OIL 




FIG. 1.2 



T-80638 



face of the regulator assembly is com- 
pressed against the distributor rotor and 
forms an end seal for the transfer pump. 

The distributor rotor incorporates two 
charging ports and a single axial bore with 
one discharge port to serve all head outlets 
to the injection lines . The weight retainer 
hub is a shrink fit to the drive end of the 
rotor . 

The hydraulic head contains the bore in 
which the rotor revolves, the metering valve 
bore, the charging ports and the head dis- 
charge fittings. The high pressure in- 
jection lines to the nozzles are fastened to 
these discharge fittings . 

The DM pump contains its own mechanical 
governor, capable of close speed reg- 
ulation . The centrifugal force of the 
weights in their retainer is transmitted 
through a sleeve to the governor arm and 



through a positive linkage to the metering 
valve . The metering valve can be closed to 
shut off fuel through a solid linkage by an 
independently operated shut-off lever . 

The automatic advance is a hydraulic 
mechanism which advances or retards the 
beginning of fuel delivery from the pump. 

B. FUEL FLOW 

The operating principles of the pump can be 
understood more readily by following the 
fuel circuit during a complete pump cycle 
(Fig. 1.2). The fuel flow for the DM4 (Fig. 
1.3) is basically the same as that of the 
DM2 (Fig. 1.4) with the exception of the 
charging of two additional plungers . Fuel is 
drawn from the supply tank through filters 
into the pump through the inlet filter screen 
(1) by the vane type fuel transfer pump (2) . 
Some fuel is by-passed through the pressure 
regulator assembly (3) to the suction side. 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

1-2 



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Construction and Operation 



CAM ROLLER 



DM4 



CAM ROLLER 



SHOE 
SHOE PLUNGER 
PLUNGER 



"^ V^W-SHIM 



LEAF SPRING SCREW 




LEAF SPRING 



CHAMFER 
INWARD 




P. /"& 



CHAMFER 
INWARD 



■C3) 



DM2 



CAM ROLLER 

SHOE 
PLUNGER 




■FIG. 1.4 



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Fuel under transfer pump pressure flows 
past the rotor retainers (4) into an annulus 
on the rotor . It then flows through a con- 
necting passage (5) in the head to the ad- 
vance (6) and also to the charging circuit (7). 
The fuel flows around the annulus (8) through 
a connecting passage to the metering valve 
(9) . The radial position of the metering 
valve, controlled by the governor, regu- 
lates the flow of fuel into the charging 
annulus (10) which incorporates the charg- 
ing ports . 

As the rotor revolves, the two inlet passages 
(11) register with the charging ports in the 
hydraulic head, allowing fuel to flow into the 
pumping chamber . With further rotation, the 
inlet passages move out of registry and the 
discharge port of the rotor registers with 
one of the head outlets . While the discharge 
port is opened, the rollers (12) contact the 
cam lobes forcing the plungers together . 
Fuel trapped between the plungers is then 
pressurized and delivered by the nozzle to 
the combustion chamber . 

With the exception of the drive shaft bearing, 
self-lubrication of the pump is an inherent 
feature of the Roosa Master design. As fuel 
at transfer pump pressure reaches the 
charging ports, slots on the rotor shank al- 
low fuel and any entrapped air to flow into 
pump housing cavity . 



In addition, an air vent passage (13) in the 
hydraulic head connects the outlet side of 
the transfer pump with the pump housing. 
This allows air and some fuel to be bled 
back to the fuel tank via the return line . The 
fuel thus by-passed fills the housing and 
lubricates the internal components . 

C. TRANSFER PUMP 

The positive displacement vane type fuel 
transfer pump consists of a stationary liner 
and spring loaded blades which are carried 
in slots in the rotor . Since the inside diam- 
eter of the liner is eccentric to the rotor 
axis, rotation causes the blades to move in 
the rotor slots. This blade movement 
changes the volume between the blade 
segments . 

Transfer pump output volume and pressure 
increase as pump speed increases . Since 
displacement of the transfer pump exceeds 
injection requirements , some of the fuel is 
recirculated by means of the transfer pump 
regulator to the inlet side of the transfer 
pump. 

Figure 1.5 illustrates the pumping principle 
Blade movement causes a volume increase 
in the quadrant between blade 1 and 2 (Fig. 
1.5a). At this time, the quadrant is in 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety 

1-3 



Construction and Operation 



INLET SLOT 




b. 



INLET 

TRANSFER PUMP PRESSURE 




OUTLET GROOVE 



FIG. 1.5 



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registry with a kidney shaped slot in the top 
portion of the regulator assembly. The in- 
creasing volume causes fuel to be pulled 
through the inlet fitting and filter screen 
into the transfer pump liner . Volume be- 
tween the two blades continues to increase 
until blade 2 passes out of registry with the 
regulator slot . At this point the rotor has 
reached a position where movement of blades 
1 and 2 is negligible and volume is not chang- 
ing (Fig. 1.5b). The fuel between the blades 
is being carried to the bottom of the trans- 
fer pump liner . 

As blade 1 passes the edge of the kidney 
shaped groove in the lower portion of the 
regulator assembly (Fig. 1.5c), the liner, 
whose inside diameter is eccentric to the 
rotor, pushes blades 1 and 2 in a direction 
opposite to their previous movement (Fig. 
1.5a). The volume between the blades is re- 
duced and pressurized fuel is delivered 
through the groove of the regulator as- 
sembly, past the rotor retainers and into 
an annulus on the rotor leading to the hy- 
draulic head passages . Volume between the 
blades continues to decrease, pressurizing 
the fuel in the quadrant, until blade 2 passes 
the groove in the regulator assembly. 

REGULATOR ASSEMBLY OPERATION 

Figure 1.6 shows the operation of the pres- 
sure regulating piston while the pump is 



running . Fuel output from the discharge side 
of the transfer pump forces the piston in the 
regulator against the regulating spring. As 
flow increases, the regulating spring is com- 
pressed until the edge of the regulating 
piston starts to uncover the pressure reg- 
ulating slot "A" (Fig. 1.6a). Since fuel 
pressure on the piston is opposed by the 
spring, the delivery pressure of the transfer 
pump is controlled by the spring rate and 
size of the regulating slot "A". Therefore 
pressure increases with speed. 

A high pressure relief slot "B" is incorporated 
in the regulator as part of the pressure re- 
gulating slot to prevent excessively high 
transfer pump pressure, if the engine or 
pump is accidentally overspeeded. 

VISCOSITY COMPENSATION 

The DM transfer pump works equally well 
with different grades of diesel fuel and 
varying temperatures, both of which affect 
fuel viscosity. A unique and simple feature 
of the regulating system offsets pressure 
changes caused by viscosity difference . 
Located in the spring adjusting plug is a 
thin plate incorporating a sharp-edged 
orifice . The orifice allows fuel leakage past 
the piston to return to the inlet side of the 
pump . Flow through a short orifice is 
virtually unaffected by viscosity changes . 



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1-4 



Construction and Operation 



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REGULATING SLOT 



REGULATING PISTON 
INLET SIDE 




REGULATING SPRING 
REGULATOR 
N PLATE 

ORIFICE 




SPRING ADJUSTING PLUG 



DISCHARGE SIDE 



H INLET 

G TRANSFER PUMP PRESSURE 



FIG. 1.6 



The biasing pressure exerted against the 
back side of the piston is determined by the 
leakage past designed clearance of the 
piston in the regulator bore and the pres- 
sure drop through the sharp edged orifice . 
With cold or viscous fuels , very little 
leakage occurs past the piston. The addi- 
tional force on the back side of the piston 
from the viscous fuel pressure is slight . 
With hot or light fuels, leakage past the 
piston increases. Fuel pressure in the 
spring cavity increases also, since flow 
through the orifice remains the same as 
with cold or viscous fuel. The increased 
fuel pressure assists the regulating spring 
and moves the piston, reducing opened re- 
gulating slot area. This variation in piston 
position compensates the leakage which 
would occur with thin fuels and design pres- 
sures are maintained over a broad range 
of viscosity changes . 

D. CHARGING AND DISCHARGING 

CHARGING CYCLE 

As the rotor revolves, (Fig. 1.7) the two 
inlet passages in the rotor register with 
ports of the charging annulus .Fuel under 



pressure from the transfer pump, con- 
trolled by the opening of the metering valve, 
flows into the pumping chamber forcing the 
plungers apart. 

The plungers move outward a distance 
proportionate to the amount of fuel required 
for injection on the following stroke . If only 
a small quantity of fuel is admitted into the 
pumping chamber, as at idling, the plungers 
move out a short distance . Maximum 
plunger travel and, consequently, maximum 
fuel delivery is limited by a single leaf 
spring (DM2) or two leaf springs (DM4) 
which contact the edge of the roller shoes. 
Only when the engine is operating at full 
load will the plungers move to the most out- 
ward position. Note (Fig. 1.7) that while the 
angled inlet passages in the rotor are in 
registry with the ports in the charging 
annulus, the rotor discharge port is not in 
registry with a head outlet. Note also that 
the rollers are off the cam lobes. Compare 
their relative positions (Fig. 1.7 and 1.8). 



Study SAFETY RULES, pages I thru III. thoroughly for the protection of personal and machine safety. 

3-5 



Construction and Operation 



METERING VALVE 



CHARGING ANNULUS 



ANNULUS IN HYDRAULIC 
HEAD 



DISTRIBUTOR ROTOR 




INLET PASSAGES 
ROLLER BETWEEN CAM LOBE 



TRANSFER PUMP 



TRANSFER PUMP PRESSURE 

-FIG. 1.7 



DISTRIBUTOR ROTOR 



DISCHARGE FITTING 




PLUNGER 

SHOE 



ROLLER 
CONTACTS 
CAM LOBE 



DISCHARGE PASSAGE 

■ INJECTION LINE PRESSURE 



FIG. 1.8 



DISCHARGE CYCLE 

As the rotor continues to revolve (Fig. 1.8), 
the inlet passages move out of registry 
with the charging ports . The rotor dis- 
charge port opens to one of the head outlets . 
The rollers then contact the cam lobes and 
injection begins . Further rotation of the 
rotor moves the rollers up the cam lobe 
ramps pushing the plungers inward . During 
this stroke the fuel trapped between the 
plungers flows through the axial passage of 
the rotor and discharge port to the injection 



line . Delivery to the injection line continues 
until the rollers pass the inner-most point 
on the cam lobe and begin to move outward . 
The pressure in the axial passage is then 
reduced, allowing the nozzle to close . This 
is the end of injection. 

E. DELIVERY VALVE FUNCTION 

The delivery valve (Fig. 1.9a and 1.9b), 
rapidly decreases injection line pressure 
after injection to a predetermined value 
lower than that of the nozzle closing pres- 
sure . This reduction in pressure causes the 
nozzle valve to return rapidly to its seat, 
achieving sharp delivery cut-off and pre- 
venting improperly atomized fuel from 
entering the combustion chamber . 

The delivery valve operates in a bore in the 
center of the distributor rotor . Note that the 
valve requires no seat - only a stop to limit 
travel. Sealing is accomplished by the close 
clearance between valve and bore into which 
it fits . Since the same delivery valve per- 
forms the function of retraction for each in- 
jection line, the result is a smooth running 
engine at all loads and speeds . 

When injection starts, fuel pressure moves 
the delivery valve slightly out of its bore and 
adds the volume of its displacement, section 
"A" ^ to the delivery valve spring chamber. 
Since the discharge port is already opened to 
a head outlet, the retraction volume and 
plunger displacement volume are delivered 
under high pressure to the nozzle . Delivery 
ends when the pressure on the plunger side 
of the delivery valve is quickly reduced, due 
to the cam rollers passing the highest point 
on the cam lobe which allows the plunger to 
move outward. 

Following this, the rotor port closes com- 
pletely and a residual injection line pres- 
sure is maintained . Note that the delivery 
valve is only required to seal while the dis- 
charged port is opened . Once the port is 
closed, residual line pressures are main- 
tained by the seal of the close fitting head 
and rotor . 



r 



c 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 



1-6 



Construction and Operation 



( 



C 



C 



DISCHARGE PORT 
DELIVERY VALVE / DELIVERY VALVE SPRING 
DISCHARGE PASSAGE / / / DELIVERY VALVE STOP 




DISTRIBUTOR 
ROTOR 



INJECTION LINE 
PRESSURE 



DELIVERY VALVE 
SCREW 



i 



RESIDUAL LINE 
/ PRESSURE 



Xi 



~\_J 



itntvfuv"" 



DELIVERY VALVE CLOSED 



-/"l 



■ INJECTION LINE PRESSURE 
ID RESIDUAL LINE PRESSURE 



FIG. 1.9 



F. RETURN OIL CIRCUIT 

Fuel under transfer pump pressure is dis- 
charged into a vent passage in the hydraulic 
head (Fig. 1.10). Flow through the passage 
is restricted by a wire to prevent excessive 
return oil and undue pressure loss. 

The vent passage is located behind the meter- 
ing valve bore and connects with a short 
vertical passage entering the governor com- 
partment . 

Should air enter the transfer pump ? it im- 
mediately passes to the vent passage as 
shown. Air and a small quantity of fuel then 
flow from the housing to the fuel tank via the 
return line . 

G. MECHANICAL GOVERNOR 

The governor serves the purpose of main- 
taining the desired engine speed within the 
operating range under various load settings . 



AIR VENT PASSAGE TO GOVERNOR 
LINKAGE COMPARTMENT 




: 1 HOUSING PRESSURE 

M TRANSFER PUMP PRESSURE 



•FIG. 1.10 



In the mechanical governor (Fig. 1.11), the 
movement of the weights acting against 
governor thrust sleeve rotates the metering 
valve by means of the governor arm and 
linkage hook. This rotation varies the registry 
of the metering valve opening to the passage 
from the transfer pump, thereby controlling 
the quantity of fuel to the plungers . The 
governor derives its energy from weights 
pivoting in the weight retainer. Centrifugal 
force tips them outward, moving the 
governor thrust sleeve against the governor 
arm. which pivots on the knife edge of the 
pivot shaft and through a simple, positive 
linkage hook, rotates the metering valve . 
The force on the governor arm caused by the 
weights is balanced by the governor spring 
force , which is controlled by the manually 
positioned throttle lever and vehicle linkage 
for the desired engine speed. 

In the event of a speed increase due to a 
load reduction, the resultant increase in 
centrifugal force of the weights rotates the 
metering valve clockwise to reduce fuel . 
This limits the speed increase (within the 
operating range) to a value determined by 
governor spring rate and setting of the 
throttle . 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety 

1-7 



Construction and Operation 



GOVERNOR ARM 



GOVERNO* 
LINKAGE HOOK / ■ ) 



WEIGHT 



THRUST SLEEVE 



WEIGHT RETAINER 




ROTTLE SHAFT 



LOW IDLE SPRING 



METERING VALVE 







^ ^4'-- : -/"- 6 ^^ ^>\ 









FIG. 1.11 



r 



( 



When the load on the engine is increased, 
the speed tends to reduce . The lower speed 
reduces the force generated by the weights 
permitting the spring force to rotate the 
metering valve in a counter-clockwise 
direction to increase fuel. The speed of the 
engine at any point within the operating range 
is dependent upon the combination of load on 
the engine and the governor spring rate and 
setting as established by the throttle position. 

A light idle spring is provided for more 
sensitive regulation when weight energy is 
low in the low end of the speed range . The 
limits of throttle travel are set by adjusting 
screws for proper low idle and high idle 
positions . 

A light tension spring takes up any slack in 
the linkage joints and also allows the shut- 



off mechanism to close the metering valve 
without having to overcome the governor 
spring force. Only a very light force is re- 
quired to rotate the metering valve to the 
closed position. 

H. AUTOMATIC ADVANCE ( Speed Advance) 

The Roosa Master design permits the use of 
a simple, direct acting hydraulic mechanism 
powered by fuel pressure from the transfer 
pump, to rotate the cam and vary delivery 
timing. The advance mechanism advances or 
retards start of fuel delivery in response to 
engine speed changes. In most injection 
systems 9 the actual beginning of de livery of 
fuel at the nozzle will start later (in engine 
degrees of rotation) as the speed increases. 



_ c 



Study SAFETY RULES, pages I thru III, thoroughly 

1- 



for the protection of personal .and machine safety. 
(Revised January 1981) 



Construction and Operation 



( 



ADVANCE DIRECTION 



PISTON HOLE PLUG 



ADVANCE PISTON 



TRANSFER PUMP PRESSURE 



FIG. 1.12a 



SPEED ADVANCE OPERATION 

END OF INJECTION TIMING VS. ENGINE SPEED 



Full Advance 




ENGINE SPEED (RPM) 



FIG. 1.13 



c 



ADVANCE DIRECTION 



Q TRANSFER PUMP PRESSURE 



DISTRIBUTOR ROTOR 



TRANSFER PUMP 
PRESSURE- 




TRIMMER SCREW 



ADVANCE SPRING 



ADVANCE PIN 



FIG. 1.12 b 



C 



Compensating this inherent "increasing in- 
jection lag" will often improve the high 
speed performance of the engine . Starting 
delivery of fuel to the nozzle earlier when 
the engine is operating at higher speed in- 
sures that combustion takes place when the 



piston is in its most effective position to 
produce optimum power with minimum 
specific fuel consumption and minimum 
smoke . 

The advance piston, located in a bore in the 
housing, engages the cam through the ad- 
vance pin and moves the cam (when fuel 
pressure moves the piston) opposite to the 
direction of rotor rotation (Fig. 1.12a, Fig. 
1 . 12 b ) . Fuel under transfer pump pres- 
sure is fed through a drilled passage in the 
hydraulic head which registers with the bore 
of the head locating screw. Fuel is then 
directed through a groove in the head locat- 
ing screw to an annulus in the piston hole 
plug . It enters a port in the piston hole plug 
leading to the reed check valve . Increasing 
transfer pump pressure forces fuel past the 
valve to the advance piston. Fuel pressure 
against the piston must overcome the 
opposing spring force plus the dynamic in- 
jection loading on the cam in order to 
change the cam position. The reed check 
valve prevents the normal tendency of the 
cam to return to the retard position during 
injection by trapping the fuel in the piston 
chamber. When engine speed decreases, 
the hydraulic pressure is reduced and the 
spring returns the cam to a retarded posi- 
tion in proportion to the reduction of speed . 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

1-9 



Construction and Operation 



The fuel in the piston chamber is allowed to 
bleed off through a control orifice in the 
piston hole plug . 

At low speeds 9 because transfer pump pres- 
sure is comparatively low, the cam re- 
mains in the retarded position . When engine 
speed increases, transfer pump pressure 
rises, which moves the piston to an ad- 



vanced position. Advance piston movement 
is related to speed . Total movement of the 
cam is limited by the piston length. 

A "trimmer screw" is provided to adjust 
advance spring preload which controls 
start of cam movement. It can be incor- 
porated at either side of the advance mecha- 
nism and may be adjusted on the engine 
while running. 



( 



c 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

1-10 



TOPIC 2 REMOVAL FROM ENGINE 



C 



DANGER 



Extinguish all smoking materials and 
open flames before working around 
diesel fuel . 



A 



WARNING 



Never use gasoline, solvent or other 
flammable fluids to clean parts . 



c 




T-80627 



FIG. 2.1 



This procedure for removal of the pump 
from the engine should be followed in detail 
to assure ease of re-installation. 



NOTE: Do not steam clean or wash down 
while the engine is operating. Severe damage 
to the pump may occur if its temperature is 
changed radically while running . 

B . Shut off the fuel supply and disconnect 
inlet and return lines from their fittings . 
Loosen injection tubing nuts at the nozzles 
and pump. 

NOTE: In removing the injection tubing nut 
from the pump, hold the discharge fitting 
with a wrench to prevent loosening from the 
hydraulic head. Immediately after the lines 
are removed, all pump, nozzles and line 
openings should be capped or plugged . 

C . Check TEST STAND DATA ( Topic 9) 
for proper timing position of crankshaft . 
Bar the engine in correct direction of 
rotation until the engine timing mark is in- 
dexed and the No . 1 cylinder is at the end of 
the compression stroke . Remove the timing 
line cover from the outboard side of the 
pump. Timing line on the governor weight 
retainer hub should be directly opposite the 
line on the cam . 

D . Disconnect throttle and shut-off linkage 
and electrical connections if used. 

E . In most cases it will be necessary to 
remove the pump drive gear from the hub or 
drive shaft . Refer to the engine manual . 

F . Support the pump with one hand and re- 
move the mounting stud nuts and washers on 
the pump flange Remove the pump from the 
engine . 



A . Clean and wash down the pump, fittings 
and all connections with non-flammable, 
non-toxic, commercial solvent to eliminate 
the possibility of contamination entering the 
system when lines are disconnected. 



e 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety 

2-1 



( 



c 



c 



TOPIC 3 DISASSEMBLY 



c 



c 



c 



^ DANGER 



Extinguish all smoking materials and 
open flames before working around 
diesel fuel . 



WARNING 



mk, Never use gasoline, solvent or other 
flammable fluids to clean parts . 

4k Wear safety glasses with side shields 
or goggles when using compressed 
air for cleaning to reduce the danger 
of personal injury from flying parti- 
cals . Limit the pressure to 30 psi 
(2 . 1 kg/cm?) according to OSHA re- 
quirements . 



Study the Manual first . Before commencing 
the disassembly of the pump, cover inlet and 
outlet holes, remove all external grease and 
dirt by washing the unit with non-flammable, 
non-toxic commercial solvent and blowing 
it off with filtered, compressed air . It must 
be constantly kept in mind that dirt, dust, 
and foreign matter are the greatest enemies 
of the fuel injection pump. As an added pre- 
caution to prevent dirt from entering the fuel 
system while servicing the pump, it is 
essential that a clean work space, clean 
tools, and clean hands be used. 

NOTE: All seals and gaskets should be dis- 
carded during disassembly. 

A clean pan should be available in which the 
parts may be placed upon disassembly, and 
a pan of clean fuel oil must be available in 
which the parts may be flushed . It is 
recommended that these by deep drawn pans 
which rounded corners to lessen the chances 
of dirt pockets . 

It is necessary for assembly to lubricate 
parts with clean diesel fuel. Make sure 
that all smoking materials are extinguished 
and no open flames and sparks are near . 
Place all parts prior to assembly in a 
closed container of clean diesel fuel for 
lubrication . 



STEP 1 Remove the pump flange seal 
from the housing (Fig. 3.1). 




FIG. 3.1 



STEP 2 Mount the pump in holding Fixture 
No. 19965. Never clamp the pump in a vise, 
always use a fixture . Remove all lead 
plumb seal wires . Unscrew the three cover 
hold-down screws (Fig. 3.2a). Remove the 
governor control cover and cover gasket 
(Fig. 3.2b). 




FIG. 3.2 a- 



Study SAFETY RULES, pages I thru III, thoroughly tor the protection of personal and machine safety. 

3-1 



Disassembly 



CONTROL COVER 




■FIG. 3.2b 




FIG. 3.4- 



( 



FULL SHUT-OFF 
POSITION 




FIG. 3.3 



THROTTLE SHAFT 
LEVER KEY 




FIG. 3.5 



c 



STEP 3 Remove the shut-off cam by rotat- 
ing the shut-off lever to the full run 
(W.O.T.) position. Place tool No c 20992, 
with tab beneath the shorter leg of the shut- 
off shaft and pry gently, sliding the cam off 
the shaft assembly (Fig. 3.3). Discard the 
shut-off cam. 



STEP 4 Remove the throttle shaft re- 
tainer clip by rotating the throttle lever to 
the full run (W.O.T.) position. Place tool 
No. 20992, with tab beneath the shorter leg 
of the retainer clip, on the throttle shaft 
and pry gently, sliding the clip off the shaft 
assembly. (Fig. 3.4) discard the retainer 
clipo 



STEP 5 Withdraw the throttle shaft as- 
sembly, and throttle shaft lever from the 
shut-off lever assembly (Fig. 3 5). To aid 
in correct reassembly, note the position of 
the throttle shaft lever key in relationship 
to the groove of the throttle shaft assembly, 




FIG. 3.6a 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety 

3-2 



Disassembly 



( 



c 



t 




•FIG. 3.6b 



MfTERING VAIVE 



STEP 6 Loosen the guide stud (Fig. 3.6a). 
Hold the governor spring and spring re- 
tainer firmly between the thumb and fore- 
finger . Lift out the governor spring com- 
ponents and guide stud (Fig. 3.6b). 




FIG. 3.7 



STEP 7 While depressing the metering 
valve assembly raise the governor linkage 
hook assembly, at the metering valve end, 
to clear the metering valve arm pin . Pull 
the linkage hook back slightly to disengage 
it from the governor arm and place it over 
the side of the housing . Do not disengage 
the linkage spring (Fig. 3.7). 

STEP 8 Remove the metering valve as- 
sembly (Fig. 3.8). 



STEP 9 Loosen and remove the transfer 
pump end cap locking screw, plate and 
washer from the hydraulic head (Fig„ 3 9). 




FIG. 3.8 




PLATE & WASHER 
SCREW 



-FIG. 3.9 




FIG. 3.10a 



STEP 10 Install end cap plug No . 20549 
into the end cap and loosen and remove the 
transfer pump end cap assembly, using the 
appropriate end cap wrench. (Fig. 3.10a 
and 3.10b). 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safetv 

3-3 



Disassembly 




[NO CAP ASSEMBLY 



■FIG. 3.10b 



ROLLPIN 
/ /REGULATOR ASSY. 



PISTON SEAL 



PISTON 
/ PLUG ASSY. 




Disassemble the transfer pump regulator 
components (Fig. 3.10c). Remove the inlet 
filter screen seal. Remove the end plate 
adjusting plug assembly with a 5/32" hex 
key wrench. Shake the regulating spring and 
piston out of the regulator assembly. Using 
Tool No. 13301 remove the regulating 
piston seal from the regulator c 

Remove the transfer pump blades and liner 
(Fig. 3.10d). 

Remove the transfer pump end cap seal 
(Fig. 3.10e). 




■FIG. 3.10d 



c 




c 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

3-4 



Disassembly 



■HEAD LOCKING SCREWS 




FIG. 3.11a 



STEP 11 Loosen the head locking screws 
and remove one screw (Fig. 3.11a). 




FIG. 3.11b 



Invert the pump and holding fixture as a 
unit in the vise . Loosen and remove the 
head locating screw (Fig. 3.11b and 3.11c). 





FIG. 3.12a 



STEP 12 Loosen and remove the advance 
screw hole plug using Tool No . 14490 
(Fig. 3.12a and 3.12b). 




FIG. 3.12b — 




FIG. 3.12c 



Insert Extractor No. 13301 into the hole in 
the advance pin and extract the pin (Fig . 
3.12c). 



FIG. 3. lie 1 3.12c). 

Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety 

3-5 



FIG. 3.12d 



FIG. 3.12e 



PLUG 



Disassembly 






FIG. 3.12f 



Loosen and remove the advance plug and 
power piston plug (Fig. 3.12d, 3.12e, 3.12f 
and 3.12g). 



TRIMMER SCREW | 

.SEALS 



SEALS. 




FIG. 3.12g- 



NOTE: The sides of the housing just above 
the advance bear a "C" or "CC" marking to 
denote pump rotation. The power side of 
the piston is located on the "C" side of a 
clockwise rotating pump and vice versa. 

Disassemble the auto advance components 
(Fig. 3.12h). 



ADVANCE PISTON 



PISTON RING 

^!§f\ Vug 

REED VALVE 



PISTON RING SEAL 




SEAL 



^ 



SEAL 



\ 



GUIDE 



PISTON HOLE PLUG 
ADJUSTING SCREW 



SEAL 



REED VALVE SCREWS 
RING 



SPRING 



PISTON RING 




# 



NUT 



\ 



S SEAL 
-SEAL 



PISTON HOLE PLUG 
-REED VALVE 



WASHER 
ADJUSTING SCREW 



PISTON RING SEAL 
^ADVANCE PISTON 



FIG. 3.12h 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

3-6 



( 



c 



Disassembly 



( 



C 



c 



HYDRAULIC HEAD ASSEMBLY 




FIG. 3.13a 



STEP 13 Return the pump and holding fix- 
ture as a unit to its initial position in the 
vise with the rear of the hydraulic head 
tilted slightly downward . Remove the re- 
maining head locking screw . Grasp the hy- 
draulic head assembly firmly in both hands 
and withdraw with a slight rotary motion 
(Fig. 3.13a and 3.13b). 

NOTE: Use caution so as not to drop the 
governor weights . 




HYDRAULIC HEAD 
ASSEMBLY 



FIG. 3.13b 





\jo 




^V \W SEAL 




/t/^^ 




/ ^ ,, THRUST WASHER 
^jC^ WEIGHT ^ s s. 






■» THRUST SLEEVE 




~ \ / // 








FIG. 


3 


.14 1 



STEP 14 To disassemble the governor , 
invert the hydraulic head and let the 
weights, governor thrust sleeve and 
washer fall into your hand (Fig. 3.14). 
Place head and rotor assembly on top of 
fixture No. 19965. 




FIG. 3.15a 



STEP 15 Loosen and remove one pivot 
shaft retainer nut and seal (Fig. 3.15a). 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

3-7 



Disassembly 




■FIG. 3.15b 



The governor arm pivot shaft, arm and 
linkage hook assembly may now be re- 
moved (Fig • 3 . 15b) . 




HUB RETAINING 
NUT t, WASHER 



FIG. 3.16a 



STEP 16 Install Tool No. 19928 on the 
gear hub, loosen and remove the hub re- 
gaining nut and washer (Fig. 3.16a). 




FIG. 3.16b 



Install Gear Hub Puller Tool No. 19924 
(Fig. 3.16b) and remove the gear hub. 



RETAINING RING 




FIG. 3.16c 



Remove the retaining ring using retaining 
ring pliers (No. 20043)(Fig. 3.16c). 

NOTE: This retaining ring is under con- 
siderable compression force . Use only the 
recommended retaining ring pliers (No . 
20043), and be extremely careful not to 
let the retaining ring slip off the pliers 
when removing. 



SPRING WASHER 




-FIG. 3.16d 

Remove the drive shaft spring washer 
(Fig. 3.16d). 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

■ 3-8 



( 



c 



Disassembly 



( 




DRIVE SHAFT 



FIG. 3.16e 




DRIVE SHAFT 



FIG. 3.17b 



The drive shaft assembly may not be re- 
moved from the housing (Fig. 3.16e). 



c 



BEARING SHOULDER RING 




DRIVE 
SHAFT 

ROLL PIN 
BEARING 



20044 



-FIG. 3.17a 



c 



NOTE: Step 17 is only necessary if damage 
has occur ed to the drive shaft, roll pin or 
ball bearing. 

STEP 17 Remove the bearing shoulder 
ring using retaining ring pliers (No . 20044) 
(Fig. 3.17a) o It may be necessary to press 
off the ball bearing assembly slightly in 
order to do this . 



Remove the drive shaft roll pin using 
diagonal pliers (Fig. 3. 17b). To re move the 
roll pin if it is broken use a 5/64" easy out 
extractor or a 3/32" carbide tipped drill. 




FIG. 3.17c 



Place drive shaft on an arbor press and 
press on the threaded end of the drive shaft 
against the ball bearing. Support the bear- 
ing inner race with Tool No. 18332 to pre- 
vent bearing damage (Fig. 3.17c). 



Study SAFETY RULES, pages I thru HI, thoroughly for the protection of personal and machine safety. 

3-9 



Disassembly 



WUIL_ 



RETAINING 
RING 




FIG. 3.18a 



STEP 18 Remove the seal retaining ring 
from the housing (Fig. 3.18a). 



ARBOR PRESS 



20268 




FIG. 3.18b 



6 




jf 




ik 




llfcd^ -Z 




^5 


y/ 




— FIG. 3.19 ■ — 



( 



Place the inner portion of tool No . 13375 
onto tool No. 20268 and press (From the 
front of the housing) the two drive shaft 
seals from the housing using an arbor press 
(Fig. 3.18b). 



NOTE: Discard these seals as they should 



ROTOR RLTAINERS 




FIG. 3.20 



c 



not be reused. 



STEP 19 Lift the liner locating ring from 
the rotor retainers (Fig. 3.19). (The early- 
design transfer pump components used a 
locating ring without a split . Remove this 
solid ring by inserting two small rods or 
hex-key wrenches into the two holes in the 
ring and prying outward) . 



STEP 20 Remove the rotor retainers 
(Fig. 3.20). 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

3-10 



Disassembly 



c 



HYDRAULIC HEAD 



SEAL 



ROTOR 




FIG. 3.21a 



c 




CAM RING 



ROTOR 



FIG. 3.21b 



STEP 21 Lift the head from the rotor 
(Fig. 3.21a). Lift the cam ring from the 
rotor (Fig. 3.21b). 



c 




?OUER 

^3 



LfAF SPRINC SCREW 



CAM ROLUR 







FIG. 3.21d 



Check and record roller-to-roller dimension 
as instructed on page 5-6, Step 7 9 DM2 or 
DM4. Compare this dimension with that 
called for on the pump specification . Re- 
move roller shoes and plungers (Fig. 3.21c 
and 3. 2 Id). Use brass Tool No. 13301 to 
push pumping plungers from their bore . 
Handle all parts carefully with clean hands 
wet with fuel oil or calibrating oil. Avoid 
handling the precision ground surface of the 
rotor . Use a 5/32" hex key wrench to 
loosen and remove the leaf spring adjusting 
screw(s), leaf spring(s) and shims (if used) 
from the rotor . 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety 

3-11 



Disassembly 



DELIVERY VALVE 

STOP 




ROTOR 



SPRING 
FIG. 3.2le 



/ 

SCREW 



Loosen and remove delivery valve stop 
screw using a 5/32" hex key wrench or 3/16' 
hex key wrench (Fig. 3.21e). The delivery 
valve stop and spring may now be removed . 
If the delivery valve does not slide freely 
from its bore, use extractor No. 13383. 
Discard the delivery valve stop . 




WEIGHT RETAINER 



RUBBER CUSHION 



FIG. 3.22b 



( 




VCUSHION RETAINER 



-FIG. 3.22a 



STEP 22 Remove the retaining rings and 
cushion retainers from the governor weight 
retainer assembly (Fig. 3.22a) 

NOTE: Discard the retaining rings since they 
should not be reused . 



Remove weight retainer and rubber cushions 
from the hub (Fig. 3.22b). 









13337 


1 / 












I 1 _ -- . 


METERING VALVE 


shim VrT 








\ 

\ — 


/>" X U\^\\ # 












ARM 






SPRING \\ 




PTP 


.3 


.23 








1' IVT 







c 



STEP 23 Remove the metering valve from 
the arm assembly with retaining ring 
pliers (No. 13337) (Fig. 3.23). 



C 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety 

3-12 



DANGER 



Extinguish all smoking materials and 
open flames before working around 
diesel fuel . 



TOPIC 4 PARTS INSPECTION 

Parts must be washed in a non-flammable, 
non-toxic, commercial solvent and then 
placed in a clean pan containing fresh fuel 
or calibrating oil . 



A 



WARNING 



mk, Never use gasoline, solvent or 
other flammable fluids to clean 
parts. 



A 



Wear safety glasses with side 
shields or goggles when using 
compressed air for cleaning to 
reduce the danger of personal in- 
jury from flying particles. Limit 
the pressure to 30 psi (2.1 
kg/cm^) according to OSHA re- 
quirements . 



It is necessary for assembly to lubricate 
parts with clean diesel fuel. Make sure that 
all smoking materials are extinguished and 
no open flames and sparks are near. Place 
all parts prior to assembly in a closed con- 
tainer of clean diesel fuel for lubrication. 

Examine all parts carefully in accordance 
with instructions which follow: 

Discard all Tt O" rings, seals, gaskets, 
weight retainer cushions and weight retain- 
ing rings . Replace with appropriate gasket 
kits . Examine all springs for fretting, wear, 
distortion or breakage . Clean and carefully 
check all bores, grooves and seal seats for 
damage or wear of any kind . 



c 



A. GENERAL INSPECTION 

Dirt is the greatest enemy of fuel injection 
pump. Keep the work area clean. 



B.DETAILED INSPECTION 



Examine For: 



Replace damaged or worn parts as nec- 
essary. 



PART GROUP 



PART 



Housing & Drive 



Housing 
Drive Shaft 
Ball Bearing 




SPECIFICALLY INSPECT: 



See Supplementary Inspection 1, Page 4.2 



Hydraulic Head Hydraulic Head X X X X 

& Rotor Vent Wire X 

Discharge Fittings X X X X 

Distributor Rotor X X X X 

Delivery Valve X X X X 

Plungers X X X X 

Cam Rollers & Shoes X X X X 

Leaf Spring! s) & Screw(s) XXX 

Cam X X X X 

Governor Weight Retainer XXX 

Governor Weights XXX 

Governor Thrust V/asher X X X X 

Governor Thrust Sleeve XXX 



Transfer Pump 



c 



X See Supplementary Inspection 2, Page 4.2 
Inside diameter of discharge fittings, 
sealing area for wear, nicks & scores 
X See Supplementary Inspection 3, Page 4.2 
X See Supplementary Inspection 4, Page 4.2 
X See Supplementary Inspection 5, Page 4.2 
X See Supplementary Inspection 6, Page 4.3 
See Supplementary Inspection 7, Page 4.3 
See Supplementary Inspection 8, Page 4.3 
Where weights pivot in retainer socket, also "E" 
ring area for wear, loose pins 
X See Supplementary Inspection 9, Page 4.3 
Contact areas for excessive wear 

Points of contact with governor arm for excessive 
wear 



End Cap 

Inlet Screen 

End Plate Adj. Plug 

Regulating Piston 

Regulator 

Blades 

Liner 

Rotor Retainers 



Screen and soldered area for breakage 
Tightness in regulator, plugged orifice, loose plate 

Inside diameter of regulator 

See Supplementary Inspection 10, Page 4.3 

Inside diameter in high pressure area for wear 



( Continued) 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

4-1 



Parts Inspection 



PART GROUP 



PART 



Governor 



Linkage 



Advance 



Linkage Hook 



Piston 

Pin 

Reed Valve 

Plugs 




c 



Pivot Shaft X 

Arm X 

Metering Valve X 

Metering Valve Arm X 



SPECIFICALLY INSPECT: 



X Chipped or worn knife edge 

X X Points of contact with thrust sleeve & pivot 
shaft for excessive wear 
X See Supplementary Inspection 11, Page 4.4 
X See Supplementary Inspection 11, Page 4.4 



XXX Metering valve pin hole 



X 


X 


X 


X 








X 


X 


X 


X 


X 








X 




X 


X 


X 




X 


X 




X 


X 


X 


X 


X 


X 


X 


X 



Bore for excessive wear 




FIG. 4.1 



C. SUPPLEMENTARY INSPECTION 

1 . Drive Shaft - Measure the distance 
across the flats of the drive tang which 
must not be less than ,430". The shaft 
diameter in the drive shaft seal area must 
be free of nicks and scratches for the seals 
to function properly . Moderate shaft wear 
from the seal lips is normal (Fig. 4„1)„ 



METERING VALVE HOLE 




HYDRAULIC HEAD 



VENT WIRE 



FIG. 4.2 



c 



3 . Distributor Rotor - Examine the radii 
contacted by the leaf spring(s) and the tang 
slot for excessive wear . Check all slots, 
charging and discharge ports for chipping 
of edges or dirt, and the rotor shank for 
major scratches . Slight erosion on the edge 
of the discharge port is considered normal . 
If damage or excessive wear is apparent, 
the head and rotor must be replaced as a 
matched unit. Final check for excessive 
wear on the rotor should be performed on 
the test stand by checking for minimum 
cranking delivery . 



2 . Hydraulic Head - Check the vent wire in 
the hydraulic head air bleed passage for 
freedom of movement. If the wire is free, 
flush the head and blow out all passages with 
clean, dry air . If vent wire is stuck, re- 
move and replace it after a thorough clean- 
ing of the passage . Refer to the proper 
specifications for the correct vent wire 

NOTE: Do not immerse this he ad in solvent 
for extended periods as sealant damage 
will result (Fig. 4.2). 

Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

4-2 



4. Delivery Valve - Inspect delivery valve 
retraction cuff for chipping or erosion of 
edges (Fig. 4„3). 



Parts Inspection 



( 



RETRACTION CUFF 




MUST BE SHARP EDGED 

FIG. 4.3 



c 



PLUNGER 




FIG. 4.4a 



PLUNGER 



DM4 




FIG. 4.4b 



c 



A 



WARNING 



Lacquer thinner and acetone are extreme- 
ly flammable and may cause an al- 
lergic reaction in some individuals ... 
Follow manufacturers recommenda- 
tions for proper use and handling . 



5 . Plungers - While holding the rotor under 
clean oil, insert the plungers into their bore . 
Insert only the longer plungers if the DM4 
pump is being examined. With thumb and 
forefinger over the shoe slots 9 tilt from 
side to side several times to determine com- 
plete freedom of movement . Interchanging 
or reversing their initial positions may be 
necessary, as these are matched parts . Re- 
peat with the short set without removing 
first set on the DM4 pump . If the plungers 
are sticking, but not visibly damaged, clean 
both plungers and bore with a soft brush and 
a solvent such as lacquer thinner or acetone. 
(See warning above) (Do not force plungers 
into their bore and do not handle rotor shank) 
(Figs. 4.4a and 4.4b). 



DM2 

"§8 


DM4 


A 
FIG. 


B 

4.5 



6 . Cam Rollers and Shoes - Check each 
roller in its shoe for freedom of rotation . 
Inspect the top edge of each shoe, where 
retained by the leaf spring, for chipping or 
excessive wear. Improved roller surfaces 
will result from long, normal operation in 
clean fuel oil (Figs 4.5a and 4.5b). 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

4-3 



Parts Inspection 



DM2 




■FIG. 4.6 




7 . Leaf Spring (s) and Screw(s) - Check 
for excessive wear at points where the 
spring(s) contacts the radii on the rotor and 
along the steps that retain the roller shoes . 
Check the adjusting screw(s) for tightness in 
the rotor (Figs. 4.6). 



CAM LOBE 




FIG. 4.7- 



8 . Cam - Since only the working portions 
of the lobes on the inside diameter are 
ground, any tool marks between lobes 
should not be considered as damage . The 
mottled appearance of the cam is from heat 
treatment rather than from operation. Care- 
fully inspect the cam lobes and edges of all 
flat surfaces . If there is evidence of spall- 
ing or flaking out, replace with a new cam. 
Improved cam lobe finish will result from 
long, normal operation in clean fuel oil 
(Fig. 4.7). 



HEEL 



l/" 




TOE 



"V 



7 



■FIG. 4.8- 



( 



9 . Governor Weights - Check pivot points 
and toe) of all weights for excessive wear 
(Fig. 4.8). 




FIG. 4.9 



c 



10 . Transfer Pump Blades - Inspect with 
the utmost care . Check for chipping on any 
of the edges, including spring bore edges, 
pitting, imbedded foreign particles or 
scoring on the rounded ends . Determine 
blade wear by measuring the length (0.538" 
minimum) . Inspect flat surfaces visually 
for deep scores . If any discrepancies are 
noted, replace both blade sets and springs 
(Fig. 4.9). 



c 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

4-4 



( 



Parts Inspection 



11. Metering Valve and Arm - Check the 
metering valve body for excessive wear. 
Be sure the metering valve arm is well 
seated and that there is no radial movement 
of the arm on the valve . Check the metering 
valve spring for distortion and the metering 
valve arm pin for wear or looseness (Fig. 
4.10). 




FIG. 4.10 



c 



c 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

4-5 



( 



c 



TOPIC 5 REASSEMBLY 



( 



c 



c 



i^ DANGER 



Extinguish all smoking materials and 
open flames before working around 
diesel fuel . 



WARMIMG 



Never use gasoline, solvent or other 
flammable fluids to clean parts . 



All parts must be thoroughly flushed in 
clean oil as they are being reassembled; do 
not wipe oil or wipe dry. Cleanliness will 
contribute to long life and trouble— free 
operation. All seals and gaskets must be 
replaced, whether visibly damaged or not. 
Gasket kits are provided for this purpose . 
Refer to PARTS CATALOG (Topic 12) for 
gasket kit part numbers . Apply clean grease 
sparingly to all seals to facilitate assembly 
and to prevent cutting . 

It is necessary for assembly to lubricate 
parts with clean diesel fuel. Make sure that 
all smoking materials are extinguished and 
no open flames and sparks are near. Place 
all parts prior to assembly in a closed con- 
tainer of clean diesel fuel for lubrication. 

IMPORTANT: Refer to the Torque Value 
Chart for proper tightening of all fasteners . 



STEP 1 To install the drive shaft seals, 
place the pump housing (flange end down) on 
an arbor press . Apply a light coating of 
lithium base grease to the housing seal bore 
and the O ,D. of the seals prior to assembly . 
If the housing seal bore is scored due to seal 
removal, apply a light coating of Gasoila 
sealing compound to the seal bore instead of 
grease. Place a new seal, with the seal lip 
facing the tool, on the short end of Tool No . 
20268 (Fig. 5.1a). Press the seal into the 
housing until the tool bottoms against the 
housing (Fig. 5.1b). Note: This seal must 
not protrude into the housing cavity. 





i 



*=£ 




20268 



FIG. 5.1b 



Invert the pump housing (flange end up) on 
the arbor press. Place a new seal, with 
seal lip facing the tool, on the short end of 
Tool No. 20268 (Fig. 5.1c) and press the 
seal into the flange end of the housing until 
the tool bottoms (Fig. 5. Id). 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-1 



Reassembly 




FIG. 5.1c 



ARBOR PRESS 




FIG. 5. Id 




FIG. 5.1e 




( 



GROOVE 



FIG. 5.2a 



ARBOR PRESS 




C 



BEARING SHOULDER RING 



FIG. 5.2b 



PRESS DRIVE SHAFT ROLL PIN 



Note the correct position of the seals, as 
shown in Fig. 5.1e. Insert the seal retaining 
ring into the groove in the housing seal bore . 

STEP 2 Install the bearing shoulder ring in 
the groove on the drive shaft using retaining 
ring pliers (No. 20044) (Fig. 5.2a). 

Place the drive shaft into the bearing on an 
arbor press with threaded end down D 
Support the bearing inner race with Tool No . 
18332 . Press the shaft into the be aring until 

Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-2 




c 



FIG. 5.2c 



f 



c 



t 



Reassembly 

the bearing shoulder ring is flush with the 
bearing (Fig. 5 2b). 

Press the drive shaft roll pin into the drive 
shaft pin hole until pin bottoms (Fig. 5.2c) . 



Gh^ 



rr=-i 




DRIVE SHAFT 



FIG. 5.3a 



STEP 3 Mount the pump housing in holding 
Fixture No. 19965 Never clamp the pump 
into a vise 9 always use a fixture. Lubricate 
the O.D. of the drive shaft bearing with 
mineral oil and install the drive shaft as- 
sembly into the housing (Figo 5.3a) » Do not 
force bearing into the housing bore . 




FIG. 5. 3b 



Place the drive shaft spring washer against 
the bearing (Fig. 5.3b). 



RETAINING RING 



RETAINING RING 




FIG. 5.3c 



Assemble the retaining ring to the housing 
so that the open ends are against the de- 
pressed area of the spring washer 9 using 
retaining ring pliers (No. 20043)(Fig. 5.3c). 

NOTE: This retaining ring will take con- 
siderable compression force to insert in the 
housing. Use the recommended retaining 
ring pliers (No . 20043) and be extremely 
careful not to let the retaining ring slip off 
the pliers when installing. 




FIG. 5.4a 



STEP 4 Assemble the gear hub to the drive 
shaft 9 with the notched portion of the gear 
hub in line with the drive shaft roll pin (Fig . 
5.4a). 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-3 



HUB RETAINING 
NUT & WASHER 




FIG. 5.4b- 



REFERENCE TORQUE VALUE CHART 




FIG. 5.4c 



Install Tool No. 19928 on the gear hub. 
Place the hub retaining washer and nut on 
the drive shaft and torque (Fig. 5.4b and 
5 ,4c) o Refer to Torque Value Chart for 
proper torque . 

NOTE: The correct torque on this nut is 
extremely important . Extensive damage to 
the pump and engine may result if the nut is 
not properly secured. 

To mechanically time any pump, determine 
the position of the timing line from Test 
Stand Data ( Topic 9) and use the Timing 



RUBBER CUSHIONS 



WEIGHT RETAINER 




FIG. 5.5a 



c 



Line Location Indicator (Tool No. 20395) 
shown on page 11-2 . 

STEP 5 Place the rubber cushions on the 
governor weight retainer pins and as- 
semble the hub to the weight retainer (Fig, 
5.5a). 



c 



RETAINER PIN 




FIG. 5.5b. 



Place the cushion retainers on the weight 
retainer pins (Fig. 5.5b). 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-4 



Reassembly 



C 



c 



e 



V 


AW 

\\v 




RETAINER 


PIN \^ 




RETAINING 


\ ( 
RING \ 




1 
i 






^lX/Pg^. 


1 

i 


A / 

[of 

-FIG. 


y^7 #Sy 




5 .<jC 



Assemble the retaining rings into the weight 
retainer pin slots with Applicator (No . 
20045)(Fig. 5.5c). 

NOTE: Do not distort the retaining rings. 
Check for proper assembly by trying to 
turn the retaining rings with a small bladed 
screw driver . They should not move under 
light pressure . 



DELIVERY VALVE 




FIG. 5.6 



STEP 6 Rinse the rotor thoroughly in clean 
fuel oil or calibrating oil . Place the rotor 
on top of holding Fixture No. 19965. Install 
the delivery valve to its bore using Ex- 
tractor Tool No. 13383. Make sure that it 
operates freely in its bore . 

NOTE: Do not mistake slight interference 
of the retractor collet in the bore for 
delivery valve sticking. If the valve is not 
secured straight and tight in the retractor 
collet f the collet diameter can drag in the 
rotor bore . 



Install delivery valve spring and a new 
delivery valve stop to the rotor bore . In- 
stallation of a used stop can result in leak- 
age and low output at cranking speeds .Start 
the delivery valve retaining screw into the 
bore using the hex end of the delivery Ex- 
tractor Tool No. 13383 or use a 3/16 M hex 
key wrench for a .250" delivery valve. 
Tighten the screw to the specified torque 
(Fig. 5.6). 

NOTE: Excessive tightening of this screw 
may cause seizure of the hydraulic head 
and rotor assembly. Insufficient torque may 
cause leaking and hard starting. 

Delivery Valve Replacement 

Delivery valves of various retraction values 
are used for different applications . Correct 
part numbers are found on individual pump 
specifications. The letters "OV" etched on 
the head of the rotor indicate a .001" over- 
size delivery valve bore . A rotor so marked 
must use a .001" oversize delivery valve. 
The oversize valve is also identified by 
blackening on both ends and in the groove on 
the delivery valve shank. Oversized delivery 
valves are intended to compensate for 
manufacturing tolerances only and are not 
to be used in a standard delivery valve bore . 
Oversize valves are not standard stocked 
parts of Fiat-Allis; and are obtainable only 
by special order to your Fiat-Allis dealer . 



CAM ROLLER 

SHOE 
PLUNGER 




^-LEAf SPRING 



FIG. 5.7a 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-5 



DM4 



LEAF SPRING SCREW 



Y=*g^ IM^SPR.NG 




Reassembly 

rotor is etched with the letter indicating 
bore size . This mark is found on the head 
of the rotor . 

If plunger replacement is required, check 
the size designation on the rotor and use 
the plunger of corresponding part number 
as indicated . 



FIG. 5.7b 



STEP 7 Remove the rotor from the holding 
fixture and submerge it in clean fuel oil or 
calibrating oil . Install the pumping plungers 
and check them for freedom of movement . 
Assemble the leaf spring(s), leaf spring ad- 
justing screw(s) and shims (if used) to the 
rotor . 

NOTE: DM4 roller shoes vary in size for 
different applications and are marked with 
a number on the end, e.g., from "-20 to 
- 10" in increments of "5". All four shoes 
must bear the same mark . The shoe size for 
a given application is determined by part 
number only . Assemble the cam rollers to 
the shoes by inserting from the end of the 
shoe. Never attempt to press a roller into 
its shoe from the outer edges, as the groove 
width at this point is less than the roller out- 
side diameter and shoe breakage may result. 
Assemble the rollers and shoes to their 
slots in the rotor head (Fig. 5.7a and 5.7b). 

Plunger Replacement: 

Since the plungers are positioned centrally 
in the bore during operation and their travel 
is extremely short, wear of plungers is 
virtually nonexistent . Replacement however, 
may be made in instances where rust or 
damage is handling has occurred. Plungers 
of any given nominal diameter are graded 
in four select fit sizes: A. B. C and D. The 



NOTE: A limited number of pumps will have 
a "-2" etched on the rotor following the 
letter grading code . This mark indicates a 
.002" oversize plunger bore. Replacement 
plungers should be ordered according to the 
oversize plunger group shown on individual 
specifications . 




FIG. 5.7c 



DM2 

Install Fixture No. 19969 in a vise (clamp- 
ing on the flat) so that the air inlet hole is 
not covered by the vise . Assemble a 1/4"- 
18 NPT fitting to the air inlet of the fixture . 
This fitting should be attached to a supply 
of clean, filtered, compressed air, re- 
gulated to a pressure between 40 and 100 
psi. Handle the rotor carefully, holding the 
rollers and shoes in their slots . Install the 
rotor assembly to the fixture on the air in- 
let side . Rotate the rotor until the rollers 
are pushed to their extreme outward position 



c 



c 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-6 



Reassembly 



( 



c 



(shoes bottomed on the leaf spring) by the 
air pressure . Using a 1" to 2" micrometer, 
measure the roller-to-roller dimension 
(Fig. 5.7c) (distance between the outer sur- 
faces of the opposed cam rollers) and com- 
pare this with the specification . To set the 
roller-to-roller dimension to the pump 
specification, turn the leaf spring adjusting 
screw inward (clockwise) to increase and 
outward (counter-clockwise) to reduce the 
roller-to-roller dimension. 

NOTE: The roller-to- roller setting provides 
a completely accurate maximum fuel adjust- 
ment and it should not differ from that 
shown in the TEST STAND DATA ( Topic 9) 




FIG. 5.7d 



c 



DM4 

Install Fixture No. 19969 in a vise (clamp- 
ing on the flat) so that the air inlet hole is 
not covered by the vise. Assemble a 1/4"- 
18 NPT fitting to the air inlet of the fixture . 
This fitting should be adapted to a supply of 
clean, filtered, compressed air, regulated 
to a pressure between 40 and 100 psi. 
Handle the rotor carefully, holding the 
rollers and shoes in their slots . Install the 



rotor assembly to the fixture on the air in- 
let side . Loosen the dial indicator retaining 
screw and slide the indicator to its outer 
limit . Rotate the rotor until the rollers are 
pushed to their extreme outward position 
(shoes bottomed on the leaf spring) by the 
air pressure. Using a 1" to 2" micrometer, 
measure the roller-to-roller dimensions 
(Fig. 5.7d) (distance between the outer 
surfaces of the opposed cam rollers) and 
compare this with the specification . To set 
the roller-to-roller dimension to the pump 
specification, set the rollers, adjusting 
each leaf spring alternately. Turn the leaf 
spring adjusting screws inward (clockwise) 
to increase and outward (counter-clockwise) 
to reduce the roller-to-roller dimensions. 
Since each roller shoe for a given cylinder 
is controlled by a separate leaf spring, it 
may be necessary to invert or interchange 
leaf springs to obtain correct dimensions on 
both sets of rollers . Roller settings of both 
cylinders must be within .003" of each 
other while maintaining the average roller- 
to-roller setting within the specification . 

Check centrality of the rollers (to assure 
that each one starts its pumping stroke at 
the same time) as follows: 

a. Rotate the rotor until one roller is 
aligned with the dial indicator plunger . 
Slide the indicator inward until plunger 
depresses it at least .010". Lock in- 
dicator retaining screw. "Zero" in in- 
dicator on high point of roller by rotat- 
ing knurled dial . 

b . Rotate rotor (either direction) until the 
next roller depresses dial indicator 
plunger . Allowable centrality is plus 
or minus .002" (total .004"). Before 
making any correction, check and re- 
cord centrality of all four rollers . 

c . If roller centrality is beyond specified 
tolerance, rollers and/or shoes can be 
interchanged. Recheck centrality after 
each change. Be sure to recheck roller- 
to-roller dimension . 

NOTE: The roller-to-roller setting pro- 
vides a completely accurate maximum fuel 
adjustment and it should not differ from that 
shown in the applicable specification. 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-7 



Reassembly 




FIG. 5.8a 



STEP 8 When the roller-to-roller adjust- 
ment is completed , remove the rotor as- 
sembly from the fixture, making sure that 
the cam rollers and shoes are not dislodged 
from their slots . Thoroughly rinse the 
rotor in clean fuel oil or calibrating oil and 
place the rotor shank end up on top of Fix- 
ture No. 19965. Place the cam ring on top 
of the rotor with the directional arrow in- 
dicating the opposite direction of pump 
rotation (Fig. 5.8a). This is necessary 
since pump rotation is always expressed as 
viewed from the drive end . The pump will 
not deliver proper fuel if the cam ring is 
incorrectly assembled. 



WARNING 



Wear safety glasses with side shields 
or goggles when using compressed air 
for cleaning to reduce the danger of 
personal injury from flying particles . 
Limit the pressure to 30 psi (2.1 
kg/cm 2 ) according to OSHA require- 
ments . 



Thoroughly rinse the hydraulic head in 
clean fuel oil or calibrating oil . Blow out 
all head passages and ports with clean, 
filtered, compressed air. Assemble the 
head to the rotor assembly (Fig. 5.8b). 




HYDRAULIC HEAD 



FIG. 5.8b 




ROTOR RETAIf 



FIG. 5.9 



REASSEMBLY OF TRANSFER PUMP 
SPRING WASHER DESIGN 

STEP 9 Insert the two rotor retainers be- 
tween the rotor and head. Position the re- 
tainers so the cutout portion is over the 
hole which the regulator assembly roll pin 
enters (Fig. 5.9). 

REASSEMBLY OF TRANSFER PUMP 
PRESSURE PLATE DESIGN 

A second style of transfer pump com- 
ponents is currently in use . Step 9-1, on 
page 5-9 and 10.1 on page 5-11, give 
instructions for reassembly of the new 
"pressure plate" design. Details for re- 
assembly of the earlier type "spring 
washer" design are contained in Step 9, 
above and Step 10 on page 5-9 . 



c 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-8 



Reassembly 



( 



C 



c 



Many of the component parts for these two 
designs are not interchangeable, and care 
should be exercised to use only the correct 
parts with each design. Upgrading of an 
early model DM2 or DM4 to the new "pres- 
sure plate" design should be performed 
only in kit form . 



^ 




ROTOR RETAINERS 



FIG. 5.9.1 



STEP 9 . 1 Assemble the rotor retainers to 
the head and rotor with the cut-out portions 
meeting over the roll pin hole in the hy- 
draulic head (Fig. 5.9.1). Rotor retainers 
for the pressure plate design are identified 
by a radial notch on the outside diameter . 




DIMPLES TOWARD REAR OF PUMP 



TRANSFER PUMP LINER 
LOCATING RING 



FIG. 5.10a 



STEP 10 The inside diameter of the trans- 
fer pump liner locating ring has dimples to 
keep the rotor retainers tight . The dimples 
are not centered longitudinally. Place the 
liner locating ring over the retainers with 
the dimples towards the rear of the pump . 
No dimples should coincide with the points 
at which the two retainers join. Do not seat 
the liner locating ring at this time (Fig. 
5.10a). 




Install the transfer pump end cap seal to 
the hydraulic head (Fig. 5.10b). The seal 
must be pushed down to the bottom of its 
groove to avoid interference with the end 
cap threads as it is installed. 



TRANSFER PUMP END CAP 




FIG. 5.10c 



The liner locating ring should be seated in 
place with the transfer pump end cap used 
as an installation tool . Install the end cap 
and thread into the hydraulic head by 
applying a slight pressure on top of the end 
cap . Rotate the cap counterclockwise until 
a slight "click" is heard. The cap threads 
will align themselves with the threads in 
the head, thus minimizing the possibility 
of cross-threading. Turn the cap clockwise 
by hand until tight . Continue tightening with 
wrench until the end cap is bottomed in the 
head (Fig. 5.10c). Remove the end cap, 
the liner locating ring should now be in 
place . 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-9 



Reassembly 




TRANSFER PUMP LINER 



FIG. 5.10d 

Insert the transfer pump liner so that the 
slot is in line with the hole which the 
regulator assembly roll pin will enter 
(Fig. 5.10d). 



ROTOR 



LINER 




TRANSFER PUMP B 



FIG. 5.10e 



Assemble springs to transfer pump blade 
halves and install the blades in their slots 
in the rotor (Fig. 5.10e). The blade springs 
must be fully compressed as they are in- 
stalled and care should be taken not to cock 
the blades during installation, as the sharp 
edge of the liner can score the blade ends . 



REGULATOR ASSEMBLY 




PLUG ASSEMBLY 



SCREEN SEAL 



FIG. 5.10f 



( 



SPRING WASHER DESIGN 

Assemble the transfer pump regulator com- 
ponents (Fig . 5 . lOf) . Install the inlet filter 
screen seal on the regulator . Using Tool 
No. 13301, place the regulating piston seal 
in the groove of the regulator . Do not roll 
over the seal when assembling. Install the 
piston to the regulator with the piston bore 
facing the inlet end of the regulator . The 
piston should not bind or stick within the 
regulator bore . Install the regulating spring , 
Install the end plate adjusting plug with a 
5/32" hex key wrench until it is flush with 
the inlet side of the regulator , 

NOTE: Do not tighten the plug any further 
at this time, as this can result in severe 
damage when the pump is completely as- 
sembled and operated. 



c 



LINER 




REGULATOR 
ASSEMBLY 



LOCATING PIN 



-FIG. 5.10g 

Assemble the regulator assembly to the 
liner (Fig. 5.10g). The locating pin must 
be in the correct hole of the regulator for 
the proper pump rotation. On the face of 

Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-10 



e 



Reassembly 



( 



C 



C 



FILTER SCREEN RETAINING WASHER 



SPRING WASHER 




FIG. 5.10h- 



TRANSFER PUMP END CAP 




FIG. 5.10 j 




INLET FILTER SCREEN 



FIG. 5.10i- 




TRANSFER PUMP LINER 
LOCATING RING 



■FIG. 5.10.1a 



STEP 10 . 1 Place the liner locating ring 
over the rotor retainers and bottom it 
against the head . The liner locating ring 
for the pressure plate design is a split ring, 
Position the split in the ring 90° from the 
split in the retainers . (Fig . 5.10.1a). 



the regulator assembly "C" or "CC TI is 
stamped for clockwise or counterclockwise 
pump rotation . 

Assemble the transfer pump spring washer 
and filter screen retaining washer to the 
regulator assembly (Fig. 5.10h). Place the 
inlet filter screen on the regulator assembly 
(Fig. 5.10i). 

Install the transfer pump end cap and thread 
into the hydraulic head by applying a slight 
pressure on top of the end cap. Rotate the 
cap counterclockwise until a slight "click" 
is heard, now turn the cap clockwise by 
hand until tight (Fig. 5.10j). 




TRANSFER PUMP 
END CAP SEAL 



FIG. 5.10.1b 



Install the oval cross section transfer pump 
seal into the hydraulic head. Rolling the 
transfer pump seal between the fingers 
will identify this seal from the round cross 
section seal used with the earlier design 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal ana machine safety. 

5-11 



Reassembly 




TRANSFER PUMP LINER 



FIG. 5.10.1C 



components . The correct seal must be 
used for each design in order to obtain the 
correct transfer pump pressure . The two 
types of transfer pump seals are not inter- 
changeable (Fig. 5.10.1b). 

Insert the transfer pump liner so that the 
slot is in line with the hole which the 
regulator assembly roll pin will enter 
(Fig. 5.10.1c). 



ROTOR 



LINER 




TRANSFER PUMP 
BLADES 



FIG. 5. 10. Id 



Assemble springs to transfer pump blade 
halves and install the blades in their slots 
in the rotor (Fig. 5. 10. Id). The blade 
springs must be fully compressed as they 
are installed and care should be taken not 
to cock the blades during installation, as 
the sharp edge of the liner can score the 
blade ends . 



REGULATOR ASSEMBLY 




PLUG ASSEMBLY 



FIG. 5.10.1e 



( 



PRESSURE PLATE DESIGN 

Assemble the transfer pump regulator com- 
ponents (Fig. 5.10. le). Install the inlet filter 
screen seal on the regulator . Using tool 
No . 13301, place the regulating piston seal 
in the groove of the regulator . Do not roll 
over the seal when assembling. Install the 
piston to the regulator with the piston bore 
facing the inlet end of the regulator . The 
piston should not bind or stick within the 
regulator bore . Install the regulating 
spring . Install the end plate adjusting plug 
with a 5/32" hex-key wrench until it is 
flush with the inlet side of the regulator . 

NOTE: Do not tighten the plug any further 
at this time, as this can result in severe 
damage when the pump is completely as- 
sembled and operated. 







REGULATOR 






^^ ASSEMBLY 


(^ 






& 




LOCATING PIN 


vV 






LINER |V 


^S^^O __^^T^ W 




— —FIG. 5. 10. If — 



Assemble the regulator assembly to the 
liner (Fig. 5. 10. If ). The locating pin must 
be in the correct hole of the regulator for 
the proper pump rotation . On the face of 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-12 



c 



Reassembly 



( 



C 



e 




FIG. 5.10.1g 



the regulator assembly "C" or "CC" is 
stamped for clockwise or counterclockwise 
pump rotation. 

Assemble the filter screen to the pressure 
plate and install the screen retaining ring 
(Fig. 5.10.1g). 




INLET FILTER SCREEN 



FIG. 5.10.1h 



Coat the beveled surface of the pressure 
plate and the threads on the outside diameter 
of the end cap with Lubriplate #630AA or 
equivalent . 

Install the assembled pressure plate and 
screen onto the transfer pump regulator 
assembly (Fig. 5. 10. In). 

Install the transfer pump end cap and 
thread into the hydraulic head by applying 
a slight pressure on top of the end cap . 
Rotate the cap counterclockwise until a 
slight "click" is heard, now turn the cap 
clockwise by hand until tight (Fig . 5 . 10 . li) . 



TRANSFER PUMP END CAP 




FIG. 5.10.H 



GOVERNOR ARM 




__ > KNIFE EDGE 



FIG. 5.11a 



STEP 11 Place the governor arm in position 
in the housing with the fork for the governor 
linkage hook assembly facing the rear of the 
pump. Insert the pivot shaft (knife edge 
facing the rear of the pump), in the arm 
slot (Fig. 5.11a). 




FIG. 5.11b 



Assemble the pivot shaft seal and nut, and 
tighten both cap nuts successively to the 
specified torque (Fig. 5.11b). 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-13 



Reassembly 




WEIGHT RETAINER 



FIG. 5.12a 



STEP 12 Remove the head and rotor as- 
sembly from the fixture . Position the 
governor weights into the retainer sockets 
(Fig. 5.12a). 




GOVERNOR THRUST 
SLEEVE 



FIG. 5.12b 



Insert the governor thrust washer and thrust 
sleeve into the lower slots of the governor 
weights by tilting the weights outward 
slightly. The two deep grooves of the thrust 
sleeve should face upward as installed (Fig; 
5 . 12b) . Sight across the tops of the as- 
sembled weights . They should all be level, 
and collapsed against the thrust sleeve . 




FIG. 5. 13a 



( 



STEP 13 The hydraulic head and rotor 
assembly, including the transfer pump 
assembly, cam ring and governor assembly, 
are now ready to be put into the housing. 
Install a new seal on the hydraulic head 
after first greasing it slightly. Apply a 
light film of clean grease around the inside 
edge of the housing and tilt the housing 
slightly downward at the rear to aid in 
assembly . Rotate the cam ring so that the 
unthreaded hole is in line with the head 
locating screw bore . This will insure 
proper position of the cam ring . Turn the 
weight retainer until the drill point on the 
end of the rotor registers with the drill 
point on the drive shaft tang . Grasp the 
hydraulic head firmly in both hands and in- 
sert it into the housing bore with a slight 
rotary motion (Fig. 5.13a and 5.13b). Do 
not force. If the assembly should jam 
during insertion, withdraw and start over . 
Make sure the assembly is wrung into 
position past the hydraulic head seal 
(Failure to do this will cause damage to the 
seal, resulting in leakage) . Slight force 
may be required to overcome the drive 
shaft spring washer force . 



c 



Study SAFETY RULES, pages I theu III, thoroughly for the protection of personal and machine safety. 

5-14 



Reassembly 



( 



C 



c 




FIG. 5.13b 







fl\ 






f 
I 

1 


Ull VlT HEAD LOCKING 
IMl «( SCREW 


p 








FIG. 5, 


.14 


t. 



STEP 14 Rotate the head assembly until 
the head locking screw holes line up with 
their corresponding holes in the housing. 
Insert the two head locking screws finger 
tight (Fig. 5.14). Do not tighten with a 
wrench until Step 26. 




FIG. 5.15a 



STEP 15 Assemble the metering valve, 
spring and shim to the arm assembly (Fig. 
5 . 15a) . 



METERING VALVE 




FIG. 5.15b 



Place the metering valve assembly into its 
bore (Fig. 5.15b). Depress and rotate the 
valve several times to insure freedom of 
movement. If valve sticks, rinse off with 
clean fuel oil or calibrating oil. Never use 
any abrasive, or the special surface treat- 
ment provided will be removed . 




•FIG. 5.16 



STEP 16 Depress the metering valve as- 
sembly and install the guide stud and washer 
into the housing and tighten (Fig . 5.16). 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-15 



Reassembly 




STEP 17 Pull back the governor linkage 
hook , stretching the spring just enough to 
assemble the hook correctly to the fork on 
the governor arm . Position the opposite end 
of the hook over the pin on the metering 
valve arm (Fig. 5.17) . Check all of the 
governor parts for freedom of movement . 




FIG. 5. 18 



STEP 18 Assemble the governor springy 
spring retainer, idle spring and idle spring 
guide on the bench. Apply a light film of 



SHUT OFF LEVER 

ASSFMBLY 



THROTTLE SHAFT 
ASSEMBLY 




FIG. 5.19 



grease to the parts in order to keep them in 
place while assembling. Install the spring 
components onto the guide stud as shown 
(Fig. 5.18). 

NOTE: Be sure the governor spring is correct- 
compare the color of the spring with color indi- 
cated in parts catalog. 

STEP 19 Apply a light film of grease to the 
throttle and shut-off shaft seals . Assemble 
the throttle shaft assembly partially through 
its bore in the housing . Slide the throttle 
shaft lever over the throttle shaft so that 
the projection in the throttle shaft lever 
bore engages the rear key way on the shaft . 
Position the forked end of the throttle lever 
so that it straddles the guide stud. As- 
semble the shut-off lever assembly with a 
slight rotary motion so as not to damage 
the seal . If the throttle shaft lever is 
correctly installed, rotating the throttle 
shaft assembly to the rear will cause com- 
pression of the governor spring (Fig. 5.19). 



( 



c 




FIG. 5.20a 



STEP 20 Invert the pump and holding fix- 
ture in the vise . Coat the seal of the head 
locating screw with clean grease . Insert 
and tighten the head locating screw to 
specified torque (Fig. 5.20a and 5.20b). 



c 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-16 



c 



/" 



Reassembly 




•FIG. 5.20b 



REED VALVE SCREWS 




PISTON HOLE PLUG 
REED VALVE 



ADJUSTING SCREW 



-PISTON RING SEAL 



-•AOVANCE PISTON 



PISTON RING 



PISTON RING SEAL. 
ADVANCE PISTON 




\j§) \ Vug 

^S&J \\ REED VALVE 



PISTON HOLE PLUG 
ADJUSTING SCREW 



FIG. 5.21a 



STEP 21 Assemble the auto advance com- 
ponents (Fig. 5.21a). Place the reed valve 
into the piston hole plug and insert and 
tighten two reed valve screws 9 using a 
5/64" hex key wrench to the specified 
torque . Install the piston ring seal, and 
ring in the groove of the advance piston. 
Complete assembly as shown in Fig. 5. 21a, 

NOTE: Be sure the advance spring is correct- 
compare the color of the spring with color indi- 
cated in parts catalog. 



TRIMMER SCREW 




FIG. 5.21b 



Install the advance plug and power piston 
plug assembly in the pump housing (Fig. 
5.21b). 

NOTE: The sides of the housing near the 
advance boss bear a "C" or "CC" marking 
to denote pump rotation. The power side of 
the piston is located on the side marked 
"C" for a clockwise rotating pump and vice 
versa . 




FIG. 5.21c 



Align the advance pin hole in advance 
piston with the unthreaded hole in the cam 
ring . Insert advance pin into the cam ring, 
ball-end first (Fig. 5.21c). It may be nec- 
essary to move the pin back and forth 
slightly to facilitate installing . 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

5-17 



Reassembly 



ADVANCE SCREW HOLE PLUG 




FIG. 5.21d 



Install the advance screw hole plug and new 
seal into the housing and tighten using 
Tool No. 14490 (Fig. 5.21d). 




FIG. 5.21e 




■FIG. 5.21f ~ 



WIDE OPEN POSITION 




THROTTLE LEVEK 



WRENCH 13379 



FIG. 5.22 



( 



STEP 22 Invert the pump and fixture in the 
vise . Prior to measuring and adjusting the 
linkage gap, hold throttle lever in wide open 
position and rotate the drive shaft in the 
proper direction of rotation until a slight 
"click" is heard, as the toes of the 
governor arm engage slots in the thrust 
sleeve . The torque screw (if used) should 
be backed out. With the throttle lever held 
in wide open position, use linkage gauge 
No. 18914 to check the clearance between 
the rear of the shut-off shaft and the vertical 
tab on the linkage hook. (Refer to TEST 
STAND DATA (Topic 9) for correct dimension) 
Adjustment of this clearance is made by 
using linkage Wrench No. 13379 to change 
the effective length of the linkage hook . 
Loosen the adjusting screw and slide link- 
age to maximum open length. Insert linkage 
Gauge No . 189 14 between vertical tab and 
shut-off shaft, and slide linkage hook to- 
gether from the rear until face of tab is 
flush against gauge . Tighten adjusting 
screw. Check adjustment and reset if re- 
quired (Fig. 5. 22). 



STEP 23 Install a new shut-off cam with 
the straight inner edge engaging the slot . 
The cam should snap into position . Install 
a new throttle shaft retainer clip with the 
straight inner edge engaging the slot. The 
clip should snap into position (Fig. 5.23). 



c 



Tighten the advance plugs to the specified 
torque (Fig . 5 . 21a and 5 . 2 If) . 



Study SAFETY RULES, pages I thru VI, thoroughly for the protection of personal and machine safety. 

5-18 



Reassembly 



( 




FIG. 5 .23 



c 




FIG. 5.24 



STEP 24 Assemble a new gasket to 
governor control cover and install cover on 
pump. Slip the flat washers and lock 
washers onto cover screws and tighten 
securely (Fig. 5.24). 



c 




£ — TV 

FIG. 5.25a 



TRANSfER PUMP ENO CAP 
/ 



^n 





PLATE & WASHER 
SCREW 



FIG. 5.25b 



STEP 25 Insert end cap plug (No. 20549) in 
the end cap and tighten the end cap to the 
specified torque, using the appropriate end 
cap wrench. 

NOTE: The transfer pump end cap inlet re- 
quires a special fitting with an "O" ring 
seal (1/2' -20 straight thread). Do not use 
a taper pipe thread type fitting as this 
could bottom and result in seizure of the 
head and rotor assembly and damage to the 
end cap threads . Assemble the end cap 
locking plate 9 washer and screw 9 to the 
head and tighten (Fig. 5.25b) . 




FIG. 5.26 



STEP 26 Tighten the two head locking 
screws to the specified torque (Fig. 5.26) 



Study SAFETY RULES, pages I thru VI, thoroughly for the protection of personal and machine safety. 

5-19 



Reassembly 




PUMP FLANGE SEAL 



FIG. 5.27 



( 



STEP 27 Remove the pump from holding 
fixture and install the pump flange seal 
(Fig. 5.27). 



c 



C 



Study SAFETY RULES, pages I thru VI, thoroughly for the protection of personal and machine safety. 

5-20 



TOPIC 6 ACCESSORIES 



( 



C 



c 



ELECTRICAL SHUT-OFF 

The Electrical Shut-Off Device may be 
furnished for "energized to run" or 
"energized to shut-off" operation. It is 
available for 12, 24 and 32 volt systems. 
Since this device is housed within the 
governor control cover, the external 
dimensions of the pump do not change . 

OPERATION 

ENERGIZED TO SHUT-OFF (ETSO): 
Energizing the coil overcomes the force of 
the shut-down coil spring, pulling the arm 
in and causing the tab on its lower end to 
contact the governor linkage hook . This 
moves the linkage hook against the governor 
linkage spring tension, rotating the meter- 
ing valve to its closed position and cutting 
off the fuel (Fig. 6.1). 

NOTE: Most ETSO applications use a coil 
with a voltage rating lower than system 
voltage to provide positive shut-off action. 
This is allowable since the coil is used 
under intermittent duty conditions . 




ENERGIZED TO SHUT OFF 
'/ ' ETSO 



FIG. 6.1 



ENERGIZED TO RUN (ETR): De-engergizing 
the coil allows the shut-down coil spring to 
release the shut-off arm. The lower end of 
the arm moves the governor linkage hook, 
rotating the metering valve to the closed 
position and cutting off the fuel (Fig. 6.2) 




ENERGIZED TO RUN 
ETR 



FIG. 6.2 




FIG. 6.3 



NOTE: Some "Energized to Run" appli- 
cations of Model "DM" pumps will in- 
corporate a mechanical override device 
for emergency use if the coil becomes in- 
operative due to electrical system failure. 
The override consists of a rod and guide 
assembly attached to the control cover 
through a tapped hole at the rear of the 
cover in a location that aligns the rod with 
the solenoid arm assembly . When the rod 
is pushed into the cover to the limit of its 
travel it contacts the solenoid arm as- 
sembly and locks it up against the solenoid, 
allowing the linkage hook to operate . Shut- 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

6-1 



Accessories 



off of the pump during an electrical failure 
is accomplished by pulling out the override 
rod. 

DISASSEMBLY 

Remove the cover screws, governor control 
cover and gasket from pump. Remove the 
cover contact nuts and washers and work the 
solenoid assembly out of the cover. Remove 
the shut off spring and arm . 

Some applications will incorporate a ground- 
ing wire assembly secured at one end to a 
contact screw and at the other end to the 
rear control cover screw in order to provide 
a grounded connection. On these applications 
a "hot" lead only is required for the opposite 
terminal . 

MECHANICAL OVERRIDE 

1. Remove the governor control cover. 

2 . Push in the control rod so that the snap 
ring is away from the inside edge of the 
guide assembly. 




RING 




GUIDE 
ASSEMBLY 



-WASHER 



MECHANICAL OVERRIDE DEVICE 



FIG. 6.4 



3 . Remove the snap ring and pull the con- 
trol rod out of the guide . 

4. Loosen and remove the cover guide, the 
washer and the seal . 



( 




£r i_r 



Touch Core and Armature 




CHECKING ARMATURE TRAVEL 

ENERGIZED TO RUN 
ENERGIZED TO SHUT OFF 



FIG. 6.5 




ADJUSTING ARMATURE TRAVEL 

ENERGIZED TO RUN 
ENERGIZED TO SHUT OFF 



FIG. 6.6 



( 



INSPECTION 

Examine the solenoid visually for cracks 
and swelling in the encapsulating material 
and looseness of the contact screws . Check 
the solenoid for a complete circuit with an 
ohmmeter . 



C 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety 

6-2 



Accessories 



( 



c 



REASSEMBLY AND ADJUSTMENT 



Assemble the shut-off arm and spring to 
the coil . Before installation of the solenoid 
assembly to the cover is made, adjustment 
of the arm travel and spring tension should 
be carried out as indicated (Figs. 6.5 
through 6.8) using tools 14067 and 14725. 
Check the linkage hook adjustment, with 
reference to Section 5, Step 20. Install new 
insulating tubes to both contact screws . In- 
sert the assembly into the governor control 
cover as a unit . Replace the insulating 
washer and assemble the contact nuts (10- 
15 inch pounds) . Mount the cover assembly, 
with new cover seal, to the pump and 
tighten securely. 




ADJUSTING SHUT-OFF TAB 



ADJUSTING SHUT-OFF TA» 



1AKE 
3TE: 



ENERGIZED TO RUN ONLY 

CERTAIN TAB (CIRCLED) DOES NOT INTERFERE WITH MEASUREMENT] 
REFER TO PUMP SPECIFICATION FOR CORRECT DIMENSION TO USE. 



FIG. 6.7 



Position exactly a> shown, with 
tool as close to spring os possible). 




Slightly spread coil 
to decrease tension 



Bend tab out to increase tension 



'Adjust spring to balance weight 
with .005 - .010 Gap as shown 
between core and armature 



ADJUSTING ARMATURE SPRING TENSION 

ENERGIZED TO RUN ONLY 



FIG. 6.8 



TESTING 



With the pump mounted on the test bench, 
the electrical shut-off device must be 
checked with designated voltage rating 
(stamped on cover) and wide open throttle 
at the following speeds: 

A. 400 RPM 

B . Full Load governor speed 

C . High idle (shut-off only) 

A good, heavy duty battery charger can be 
used as long as voltage can be selected and 
will hold with minimum drop (1/2 volt max.) 
during application to the solenoid coil. 

Connect battery charger to the electrical 
shut-off device before applying power to 
charger. This will reduce the possibility 
of a spark at the pump . 



c 



REASSEMBLY-MECHANICAL OVERRIDE 

1 . Screw guide into the rear of the governor 
cover, securing the washer and seal. 

2 . Push in the control rod and secure it 
from the inside with the snap ring . 

3 . During normal run conditions when the 
electric shut-off is in operating position, 
keep the rod extended to its full outward 
movement . 



Use of small, inexpensive trickle chargers 
is not recommended, since a voltage drop 
of 2-3 volts can be expected when current 
is applied to the coil . This can result in 
questionable operation and rejection of 
good coils under some conditions . 

NOTE: Do not attempt to check solenoid 
operation with the cover removed from the 
pump. The governor linkage spring aids 
operation when the cover is assembled. 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 

6-3 (Revised January 1981) 



MEMO 



( 



C 



C 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 

6-4 (Revised January 1981) 



MEMO 



c 



c 



c 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel 

g_5 (Revised January 1981) 



Accessories 




FIG. 6.15 



ANEROID 

A pressure sensitive fuel reduction control 
commonly called an "Aneroid" is in use on 
some turbocharged engine applications . 
The aneroid matches pump fuel delivery- 
quantity to engine intake manifold pressure 
during periods of acceleration. 

During acceleration, while the injection 
pump delivers full load fuel quantity, turbo- 
charger speed lags engine speed . Until full 
turbo speed is attained, insufficient air is 
supplied to the engine for complete com- 
bustion of full load fuel quantity . A re- 
duction in the full load fuel quantity delivered 
during acceleration is required to prevent 
overfueling and excessive smoke. The 
aneroid senses intake manifold pressure ' 
and reduced fuel quantity until the turbo- 
charger comes up to speed and is able to 
provide enough air for efficient combustion. 
This device is developed for each speci- 
fication and sold for original equipment 
engine applications. 




( 



FIG. 6.16 



OPERATION 



c 



At rated speed and load, when manifold 
pressure is at its peak, the aneroid piston 
is pushed outward positioning its operating 
rod and pump shut-off lever in the "Run" 
position . A decrease in intake manifold 
pressure allows the spring loaded piston to 
pull the lever toward the shut-off position . 
As the lever is moved forward, the shut- 
off cam pushes the linkage hook slightly to 
the rear, reducing fuel flow past the meter- 
ing valve, as shown in Fig. 6.16. The 
amount of fuel reduction is determined by 
the setting of the forward screw on the ad- 
justable shut-off lever . 

As turbocharger speed increases, intake 
manifold pressure overcomes the force of 
the aneroid spring, and the piston pushes 
the shut-off lever to the full "Run" position 
allowing full load fuel delivery . 



e 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

6-6 (Revised January 1981) 



Accessories 



( 




Aneroid Body & Piston Assy. 



'Bracket & Screws 



liody Retaining Nut 



Hoot 



Operating Rod 



Retaining Rings 



FIG. 6.17 



c 



Checking Aneroid Operation: 

The operation of the aneroid may be checked 
before disturbing adjustments by connecting 
a regulated air pressure source to the boost 
pressure inlet fitting. A mercury manometer 
is preferable to a gauge for measuring air 
pressure, as operating pressures are very 
low . If a gauge is used, one with a range of 
zero to 30 psi, calibrated in half-pound in- 
crements should be obtained. Refer to 
TEST STAND DATA ( Topic 9) for the 




FIG. 6.18 



correct aneroid settings for each application, 
Removal and Disassembly: 

1 . Remove boost line connection from 
aneroid inlet. 

2 . Remove both operating rod retaining 
"E" rings using snap ring pliers 13337. 

3 . Remove aneroid bracket mounting s 
screws . The aneroid and bracket as- 
sembly may now be removed from the 
pump. 

4 . If binding of the piston or leakage was 
apparent during test, the aneroid body 
and piston assembly should be replaced. 
Do not attempt to disassemble the 
aneroid body and piston assembly . It is 
a sealed unit, and serviceable only by 
replacement . 

5 . Clamp the aneroid bracket in a vise . 

6 . Separate the boot from the aneroid 
body and unscrew the operating rod . 

7 . Remove the aneroid body retaining nut, 
using tool 18031. 

NOTE: The shape of the aneroid bracket is 
designed for each application to allow con- 
venient positioning of the Aneroid, and 
several different brackets are in use . 
Servicing procedures are the same for all 
configurations . 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

6-7 



Accessories 



NOTE: Do not submerge the aneroid as- 
sembly in oil or solvents . A dry lubricant 
is used on the internal diaphragm . Washing 
of . the assembly will remove the lubricant 
and possibly damage the diaphragm . 

Reassembly: 

1 . With the mounting bracket secured in a 
vise , attach the aneroid body to the 
bracket, positioning the aneroid inlet 
according to TEST STAND DATA 

( Topic 9) . Assemble the retaining nut to 
the body and tighten to 80 to 90 ft .-lbs ., 
using tool 18031. 

2 . Attach a new boot to the opening rod and 
thread the rod into the piston. Avoid 
twisting the piston, as this may cause 
damage or binding of the internal dia- 
phragm . When the operating rod bottoms 
in the piston, back it out approximately 
two turns to allow for repositioning of 
the rod . Do not attach the boot to the 
aneroid body at this time . 

3 . Fasten aneroid bracket to pump with 
bracket retaining screws . 

4 . Do not attach operating rod to pump shut- 
off lever until pump is calibrated and 
preliminary adjustments are made . 

TEST STAND ADJUSTMENTS 

NOTE: All adjustments are made with 
throttle lever in full fuel position (W.O.T.). 

1. Calibrate pump with aneroid operating 
rod disconnected from shut-off lever, 
and shut-off lever in "Run" position. 



2 . After pump performance is checked, set 
forward shut-off adjusting screw for the 
required delivery according to TEST 
STAND DATA (Topic 9) . The pump may 
now be removed from the test stand. 

Aneroid Adjustments: 

1. Set rear shut-off adjusting screw to 
obtain lever travel required on pump 
specification sheet. Lever travel is 
measured at lever hole as shown in Fig. 
6.18. 

2 . Connect aneroid operating rod to the 
pump shut-off lever and connect a 
regulated air pressure source to the 
aneroid inlet. Note pressure at which 
shut-off lever lifts off forward adjusting 
screw and pressure required to obtain 
full travel of lever . Lift off pressure 
may be checked by inserting a piece of 
shim stock beneath the forward adjusting 
screw . The shim will slip free as lever 
movement begins . 

3 . If the lever travel requires more pres- 
sure than indicated on pump specifi- 
cation sheet, lengthen the operating rod. 
If lever travel requires less pressure 
than indicated shorten the operating rod . 

4. Once aneroid is set, recheck reponse 
and repeatability. 

5 . Attach boot to aneroid body groove . 

Replacement During Dynamometer Test: 

The aneroid assembly, if found to be in- 
operative during dynamometer testing, may 
be replaced without removing the pump from 
the engine . The aneroid may be properly 
set by employing a mercury manometer to 
measure engine intake manifold pressure, 
and following instructions outlined in this 
Topic and TEST STAND DATA ( Topic 9) . 



( 



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c 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

6-8 



TOPIC 7 TORQUE CONTROL 



( 




FIG. 7.1 



c 





SPILL PORT 


ROTATION / 


f y/J // DISCHARGE PORT 


* 


T\l />^^ 




^-A^X^ 




CHARGING PORT 




FIG. 7.2a 



c 



TORQUE SCREW 

Torque is commonly defined as the turning 
moment or "lugging ability" of an engine. 
Maximum torque varies at each speed in the 
operating range for two reasons: (1) as 
engine speed increases, friction losses 
progressively increase and, (2) combustion 
chamber efficiency drops due to loss of 
volumetric efficiency (breathing ability of 
an engine) , and due to reduction of time 
necessary to completely and cleanly burn 



SPILL PASSAGE CHARGING PORT 

DISCHARGE FITTING 



ROTOR 




CAM LOBE 



FIG. 7.2b 



the fuel in the cylinder . Since torque in- 
creases with increased load conditions a 
predetermined point at which maximum 
torque is desired may be selected for any 
engine. Thus, as engine RPM decreases, 
the torque generally increases toward this 
preselected point . This desirable feature is 
called "Torque Back- Up". Three basic 
factors affect Torque Back-Up. These are: 

1 . Metering valve opening area 

2 . Time allowed for charging 

3 . Transfer pump pressure curve 

Of these, the only control between engines 
for purposes of establishing a desired 
torque curve is the transfer pump pressure 
curve and metering valve opening, since 
the other factors involved are common to all 
engines . Torque control in the fuel injection 
pump is accomplished in the following 
manner . 

The manufacturer determines at what speed 
for a specific application he wants his engine 
to develop its maximum torque . The maxi- 
mum fuel setting is then adjusted for re- 
quired delivery during dynamometer test. 
This delivery must provide acceptable fuel 
economy. The engine is then brought to full 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

7-1 



Torque Control 



TDC 




TDC 



Normal Fuel Delivery at 
Full Advance 



load governed speed . The fuel delivery is 
then reduced from that determined by the 
maximum fuel setting by turning in an ad- 
justment or "torque screw" (Fig. 7.1), 
which moves the metering valve toward the 
closed position. The engine is now running 
at full load governed speed. When the engine 
is operating at high idle speed, no-load, the 
quantity of fuel delivered is controlled only 
by governor action through the metering 
valve. 

NOTE: At this point, the torque screw and 
maximum fuel adjustment have no effect . 
As load is applied, the quantity of fuel 
delivered is controlled only by governor 
action and metering valve position until full- 
load governed speed is reached. At this 
point, further opening of the metering valve 
is prevented by its contact with the previously 
adjusted torque screw. Thus, the amount of 
fuel delivered at full-load governed speed is 
controlled by the torque screw and not by 
the roller-to-roller dimension. As additional 
load is applied and engine RPM decreases, a 
greater quantity of fuel is allowed to pass 
into the pumping chamber due to the in- 
creased time of registration of the charging 



SPILL PORT REGISTERS WITH 
HEAD CHARGING PORT 



Reduced Fuel Delivery at 
Retarded Timing 



FIG. 7.2c 



ports . During this phase of operation the 
metering valve position remains unchanged, 
still being held from further rotation by the 
torque screw . As engine RPM continues to 
decrease, the rotor charging ports remain 
in registry for a longer time period allow- 
ing a larger quantity of fuel into the pumping 
chamber . Fuel delivery increases until the 
predetermined point of maximum torque is 
reached. At this point the quantity of fuel is 
controlled by the roller-to-roller dimension . 
It must be remembered that torque adjust- 
ment on the pump may be properly carried 
out only during dynamometer or bench test . 
It should not be attempted on a unit in the 
field without means of determining actual 
fuel delivery . 

SPILL PORT/TORQUE CHOPPER 

A fuel delivery control system which 
operates in conjunction with the speed ad- 
vance mechanism has been developed for 
use in some Model DM injection pumps . The 
system is known as the Spill Port /Torque 
Chopper and uses a special hydraulic rotor 
with a spill passage drilled into the rotor 
bore between the pumping plungers and the 



( 



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Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

7-2 



Torque Control 



( 



delivery valve . The spill passage is located 
radially following the rotor charging passage 
as shown in Fig. 7.2a . 

During retarded injection timing, the 
location of the spill port allows high pres- 
sure to flow back through the spill passage 
and into the charging annulus via a head 
charging port prior to the normal end of 
injection. High pressure spilling, as shown 
in Fig. 7.2b, can only occur when the ad- 
vance mechanism has positioned the cam in 
a retarded direction. 

As the cam advances injection occurs 
earlier and spilling is reduced. At full ad- 
vance , injection is completed before the 
spill port comes into registry with a head 
charging port . 

Decreasing advance, as a result of reduced 
engine speed and transfer pump pressure, 
permits more spilling as the spill port 
comes into registry with a head charging 
port while injection is still occurring. 



c 



The combined effect of the Spill Port/ 
Torque Chopper and speed advance 
mechanism is to reduce fuel delivery as 
engine speed drops . The reduced fuel 
delivery and lower engine output torque 
result in reduced exhaust smoke as engine 
speed decreases . 



The adjustment procedure for pumps 
equipped with the Spill Port/ Torque 
Chopper is important and must be followed 
exactly. While the roller-to-roller setting is 
responsible for determining full load fuel at 
full rated speed, the advance mechanism is 
adjusted to obtain the fuel delivery required 
at reduced engine speed and the desired 
engine peak torque speed . On pumps 
equipped with speed/light load advance, ad- 
justment of both the speed advance trimmer 
screw and the load advance trimmer screw 
may be required . Once these adjustments 
are completed, fuel delivery at all check- 
points should coincide with the performance 
requirements listed in TEST STAND DATA 
( Topic 9) . 



c 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

7-3 



( 



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( 



TOPIC 8 TEST BENCH DATA 



( 



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A. BENCH COMPONENT AND TEST FLUID 
RECOMMENDATIONS 

TEST BENCH HORSEPOWER 

Because engine horsepower ratings, and in- 
jection pump fuel flows have substantially- 
increased in the last few years, Fiat-Allis, 
today, recommends TEST BENCH CAPACITY 
BE A MINIMUM OF 7.5 kw (10 horse power). 
Although test benches of 5.6 kw (7.5 horse 
power)/ are usually acceptable, even these 
benches can be stalled out when testing the 
larger fuel pumps; it is important to note that 
even though the bench does not completely 
stall, erratic flows, questionable data and a 
decrease in bench life may be experienced. 

For those Fiat-Allis dealers who do not have 
enough fuel injection pump overhaul business 
to warrant the expense of an adequate heavy 
duty test bench, it is recommended that they 
use the facilities of their local Rossa- Master 
service station for their Ross-Master pump 
repairs and adjustments. 

IMPORTANT: To be certain your pump is 
calibrated using the most current data, we 
advise supplying the Roosa-Master Service 
Station with a copy of the appropriate data 
from this manual as well as the calibration 
procedures. 

TEST BENCH SUPPLY LINES 

Flexible, transparent hose is recommended; 
this will allow pump metering action surge 
pressures to dissapate; it will also allow fuel 
flow observation to determine when fuel is 
free of air bubbles. 

TEST BENCH FILTERS 

Primary filter size- -maximum, 30 micron. 

Final stage filter size- -maximum, 5 micron. 

CALIBRATION FLUID 

The meaningful difference in calibrating fluids 
(as utilized for testing outlined in this manual) 
is basically viscosity. Note also that viscosity 
changes as the temperature of the fluid changes. 
Therefore, even though the various bench 
manufacturers may state their particular fluid 
viscosity and temperature requirements 
differently, the calibration testing data 
obtained (when using fluid of the following 
SAE recommendation at the specified pump 
test temperature recommendation) will be 
acceptable in all cases. 



NOTE: The fluid recommend by the SAE is, 
SAE J-967d. A fluid meeting this specifi- 
cation has been developed by the Viscosity 
Oil Co. under specification: 

Viscor Calibration Fluid #1467 

"Viscor" may be purchased from: 
Viscosity Oil Co. 
32 00 Western Avenue 
Chicago, 111., 60608 

Other acceptable fluids are: 
Allis- Chalmers 
Part #4040036 
Roosa-Master "S.B. 201" 
Fiat "CFB" 

(Standardization Spec. #55787) 
-Not available in North America- 

FLUID SPECIFICATIONS 

The calibrating fluid shall be formulated from 
straight- run, low odor fuel stocks containing 
the additives as required to meet the fluid 
specifications: (See chart on next page). 

CALIBRATING FLUID CHANGE PERIOD 

Change calibrating fluid every 6 months, or 
200 pump tests (whichever comes first) or at 
any time the fluid viscosity falls out of a 
viscosity range of 34 -- 38 SUS (2.4 -- 3. 18 
cSt kinomatic viscosity) at 37°C (100°F). 

TEST BENCH FLUID HEATER 

The test bench calibration fluid heater must 
be capable of controlling the fluid temperature 
within 5° at a temperature range of 38° -- 
49°C (100° -- 120 a F); this accuracy will 
cover the range of test recommendations. 

Roosa-Master and SAE recommend 43 -- 
46°C (110° -- 115°F). 

FLUID GRADUATES (ACCUMULATORS) 

The graduation accuracy of the graduates 
(may be called accumulators or test measure 
tubes) should be within 1% of the full scale; 
the graduations should be 1% of full scale. 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 
SERVICE MANUAL (Revised January 197 9) 

FORM 73112988 8 _ L 



Test Bench Data 



FLUID SPECIFICATION CHART 



PROPERTY 


SPECIFICATION LIMIT 


TEST DESIGNATION 


Viscosity at 100°F (37.8°C) 


2.40-2.85 (2.40-2.85) est (mm 2 /s 


ASTM D 445 


Viscosity at 100°F (37.8°C) 


34.0-35.5 SUS 


ASTM D 2161 


Specific Gravity (60/60°F) 






(15.5/15.5°C) 


0.820-0.830 


ASTM D 1298 


Gravity, API 60°F (15.5°C) 


39-41 


ASTM D 287 


Color, ASTM, maximum 


3 


ASTM D 1500 


Color, ASTM, after storage of 6 
months at 110-5°F 
(43.3-2.8 C), maximum 


4 


ASTM D 1500 










Corrosion at 212°F (100°C), 


Pass -Classification 1 


ASTM D 130 


after 3 hours, copper 






Galvanic corrosion 


Pass- 10 days 


FSTM 5322. 1 


Sulfur, % weight, maximum 


0.4 


ASTM E 129 


Distillation at 20% point, max. 


470°F (243°C) 


ASTM D 86 


Flash point (P.M. closed cup), 


170°F (76.7°C) 


ASTM D 93 


minute s 






Trace sediment, % volume, max. 


0.01 


ASTM D 2273 


Foaming tendency at 75 F 


50 


ASTM D 982 


(23.9 C) after minutes 






blowing, ml. maximum 






Foam stability at 75 F 





ASTM D 892 


(23.9 C) after 2 minutes 






settling ml, maximum 






Rust protection (humidity 


Pass- 100 hours 


ASTM D 1748 


cabinet) sand blasted panel 


Pass five out of six faces of panels 
tested according to ASTM 1748 





For maximum drainage efficiency, the 
graduate rack should be capable of tilting 
about 45 (unless of bottom draining type). 
The graduates should be allowed to drain 
about 30 -- 40 seconds, and equal drain 
times should be used to avoid variations in 
subsequent readings. 

Note that the fluid level in the graduates is 
not straight across the tube, but curves 

(f ■ — l); the curve is called a meniscus; 

always read the bottom of the meniscus to 
obtain maximum accuracy. 

TEST BENCH COUNTER MECHANISM 

The construction should be positive and fast 
acting. On and off motion should be approxi- 
mately the same speed. Counter should be of 



the predetermining type and should allow 
collection of at least the following counts: 
200 and 500 strokes. The larger number of 
strokes tends to reduce the effect of the 
small counting error occurring during start- 
ing and stopping of the counting mechanism. 

CALIBRATING NOZZLES 

The following chart identifies the test bench 
nozzles which may be used for calibration 
purposes. 

IMPORTANT: Calibration (test bench) nozzles 
may not be interchanged with engine nozzles; 
engine nozzles may not be used for calibration 
purposes unless the given calibration data 
specifically states that engine nozzles and/or 
holders are to be used. 



( 



C 



F.I. P. AND 
MANUFACTURER 


ENGINE 


NOZZLE AND HOLDER 


TEST NOZZLES 


HOLDERS 


Roos a- Master 


2900 
3500 
11000 


12SD12 
12SD12 
8S2C 


EFEP 182 
EFEP 182 


BKB50SD 
BKB50SD 
BKB50SD 



Study SAFETY RULES in the front of this 
SERVICE MANUAL 
FORM 73112988 



manual thoroughly for the protection of machine and safety of personnel. 

8-2 (Revised January 1979) 



Test Bench Data 



c 



c 




Also, test bench calibration fluid must be 
used. 



T-50066 
■ FIG. 8-1 FUEL INJECTION NOZZLE - 
TESTER 

1. Pressure adjusting screws 

2. Adjusting screw locknut 

3. Filler cap 

4. Pressure gauge 

5. Valve handle 

6. Tester handle (pump) 

7. Spray collector 

8. Nozzle-holder assembly 



NOTE: Part numbers, ADN. .. (nozzles) and 
AKB. . . (holders) are American Bosch part 
numbers; EFE P. .. and EF. . .numbers are 
Robert Bosch part numbers. 

CALIBRATING NOZZLE TESTING 

NOTE: Nozzle assemblies should be tested 
at least monthly, or after each 20 pumps 
have been tested. 

Calibrating nozzles must be handled as you 
would handle a delicate gauge. In this respect, 
the nozzles should not be disassembled for 
repair unless your shop is completely 
equipped; "equipped", will include a master 
calibrating fuel injection pump. 

Unless "completely equipped", only two 
tests should be made; pressure test and 
nozzle seating test. To properly test a 
nozzle and holder assembly, a nozzle tester 
(with a recently calibrated gauge) similar 
to the one shown in Fig. 8-1 is required. 



WARNING 



Keep hands away from nozzle tip when 
popping a nozzle. The finely atomized fuel 
is ejected with sufficient force to penetrate 
the skin and cause blood poisoning. Also, 
wear safety glasses with side shields or 
goggles when popping a nozzle. 



PRESSURE TEST 

Install nozzle holder assembly on nozzle 
tester as shown in Fig. 8-1 . Install spray 
collector. 

Open nozzle tester valve and operate the 
handle several strokes to force the air out 
of the nozzle assembly. 

Operate tester handle a few quick strokes 
then observe the opening pressure (should 
be 2500 psi -- 175.8 kg/cm 2 ) 

Adjust the fuel injection nozzle to obtain 
specified opening pressure (if necessary) 
as follows: 

Remove the cap nut from the upper end of 
the fuel injection nozzle holder and loosen 
the adjusting screw locknut. 

While operating the tester pump handle, turn 
the pressure adjusting screw IN to increase 
or OUT to decrease the opening pressure 
until the specified pressure is obtained. At 
this time, hold the adjusting screw from 
turning and tighten the adjusting screw lock- 
nut to the specified torque as follows: 

NOZZLE NO. TORQUE 

ADN8S2C 44--58 (6—8 m-kg) 

ADNI2SD12 44— 58ft. lbs. (6-8 m-kg) 

EFEP 182 44— 58ft. lbs. (6-8 m-kg) 

On all tests, check for leakage between 
nozzle and holder bodies — a slight seepage is 
permissable. 

NOZZLE VALVE SEATING TEST 

Slowly operate tester until nozzle opens. 

Wipe the tip of nozzle until thoroughly dry. 



c 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 

SERVICE MANUAL 8-3 (Revised January 197 9) 

FORM 73112 988 



Test Bench Data 



WARNING' 



Keep hands and face away from the lossen- 
ed line nuts while performing fuel line and 
nozzle tests. Also, wear safety glasses 
with side shields or goggles. 



Again operate tester until pressure is approxi- 
mately 155. 14 bar (2250 psi) somewhat less 
than specified. Maintain this pressure and 
watch the nozzle tip for leakage. The nozzle 
Ls considered leak free if the droplet which 
has formed at the orifice has not fallen from 
nozzle within 10 seconds. If nozzle leaks, re- 
turn nozzle and holder assembly to place of 
purchase for reconditioning and "Master Pump 
Testing". 

HIGH PRESSURE CALIBRATION TUBING 

All tubing sets must be of the same length, 
inside diameter, and outside diameter. Tubing 
should be capped during storage and flushed 
clean before usage. Tubing end bores should 
be checked for crimping using suitable drill 
gauges; always flush-clean tubing after drilling 
or reaming. 

Tubing can be checked for flow accuracy by 
switching one tube for another (within set) and 
comparing draw results on the test bench. 

Tubing size for use with 12SD12 or 8S2C 
nozzles must be: 

I.D 2.4mm (.094") 

O.D 6.35mm (.250") 

Length 508mm (20 n ) 

NOTE: SAE orifice plate nozzles may not be 
used in place of 12SD12 or 8S2C nozzles unless 
specific SAE calibration data is used. Too, 
the nozzle opening pressure, and tubing size is 
different. 

TEST STAND ADAPTORS 

Adaptors for all Roosa-Master pumps are 
available from the test stand manufacturers 
for the following: 

American Bosch TSE 4500 

Bacharach - GP-500C 

Unitest U7000: U4500 

Hartridge Majestic - Powermaster 

TEST STAND MAINTENANCE 

Daily: 

Check hole size at the ends of injection 
lines with the chuck end of a drill bit of 
the same size as the I. D. of the lines. 
If the hole is restricted, use the drill to 
bore it out to the original size. 



Weekly: 

Check the collector system thoroughly 
for evidence of leakage. Correct as 
necessary. 

Monthly: 

1. Check nozzle holder opening pressure 
with a hand pump. 

2. Check temperature and pressure gauges 
against other gauges known to be 
accurate. If gauges are out of adjust- 
ment, have them repaired locally. 

3. Check tachometer with stroboscope or 
hand tachometer. Repair locally if 
necessary. 

4. Change calibrating oil. Be sure to use 
only approved calibrating oil. 

Quarterly: 

1. Change calibrating and lube oil filters. 
Use original manufacturer's replace- 
ment parts; do not use substitute - 
"will-fit" parts. 

2. Verify calibration of the test stand 
with the master pump as outlined in 
instructions included with the master 
pump. 

Bi- Annually: 

1. Change lube oil. 

Annually: 

1. Return the complete set of calibrating 
nozzles and holders to the manufacturer 
for inspection and reconditioning. 

Time intervals recommended here are based 
on constant daily use of the test stand. The 
intervals may be adjusted according to the 
amount each stand is used. 

B. CHECKING BENCH DRIVE SHAFT 
ALIGNMENT 

IMPORTANT: To avoid serious pump damage, 
always check bench drive shaft parallel and 
angular alignment. A guide for checking is as 
follows : 

Parallel Alignment (Fig. 8-2 ) - The pump 
mounting bracket pilot diameter must be held 
within . 127 mm (. 005"). Total Indicator 
Reading with the outboard end of the test 
stand drive shaft. The mounting bracket 
should be in the immediate area of the test 
bench bed where the pump is normally 
mounted and connected for this measurement. 
Remove the test stand drive coupling and 
mount a dial indicator extending directly 
from the test stand drive shaft to the mount- 
ing bracket pilot. Depress indicator approxi- 
mately .254 mm (.010") and set to "zero". 
Rotate the test stand drive shaft 360° by hand 



( 



C 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 
SERVICE MANUAL 8-4 (Revised January 1979) 

FORM 73112988 



Test Bench Data 



( 




VIEW FROM ABOVE 



EE3-<EE3, 



VIEW FROM SIDE 
PARALLEL MISALIGNMENT 



FIG. 8-2 



C 



c 




VIEW FROM ABOVE 



EE3 

VIEW FR 

ri 7 "B TT 



VIEW FROM SIDE 
ANGULAR MISALIGNMENT 




FIG. 8-3 



while watching the indicator. Should the 
measurement exceed .12 7 mm (. 005") shim 
the bracket mounting supports as required to 
correct the alignment. If unable to correct 
the bracket mounting supports, consult the 
test stand manufacturer. 



Angular Alignment (Fig. 8-3 ) - The pump 
mounting bracket front face must be held 
within .254 mm (.010") Total Indicator Read- 
ing with the outboard end of the test stand 
drive shaft. With the same set up as parallel 
alignment, extend the dial indicator to the 
front face of the mounting bracket. Depress 
indicator approximately .254 mm (010") and 
set to "zero". Rotate the test stand drive 
shaft 360° by hand while watching the in- 
dicator. Should the measurement exceed 
.254 mm (.010") shim the bracket mounting 
supports as required to correct the align- 
ment. If unable to correct the bracket mount- 
ing supports, consult the test stand manu- 
facturer. 

The pump drive shaft must not be deflected 
by the test stand drive shaft. There should 
be- . 025 -- . 127 mm (. 001 to . 005" ) gap 
between the shaft coupling surfaces. 

The test stand coupling should be of the 
self- aligning, no backlash type; similar to 
the Thomas Coupling (SAE J969a). 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 

SERVICE MANUAL 8-5 (Added January 1979) 

FORM 73112988 



( 



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e 



TOPIC 9 FUEL INJECTION PUMP REFERENCES, 
CALIBRATION PROCEDURES AND DATA 



A. REFERENCES 

Timed to this cylinder (viewed from end plate) 



® 





F/A PUMP NO. 


MFG. PUMP NO. 


MODEL 


ENGINE 


PAGE NO. 


74008318 * 


DM4629RH3260 


605-B 


2900 


9-4 


74008322 * 


DM4629RH3259 


545-B 


2900 


9-4 


74008551 * 


DM4629RP3278 


545-B 


649T 


9-4 


74008552 * 


DM4629RP3279 


605-B 


649T 


9-4 


74035827 * 


DM4631RH3230 


645-B 


3500 


9-7 


74036268 * 


DM4629RH3277 


645-B 


3500 


9-6 


74321756 * 


DM4631AJ3069 


100-C *\ 
150-C / 


11000 


9-6 


74321756 * 


DM4631AJ3069 


100-C \ 
150-C J 


685T 


9-6 


74321882 ** 


DM4631AJ3117 


200-C 


11000 


9-7 


74321924 ** 


DM4631FB3129 


745-C 


11000 


9-5 


74321973 ** 


DM463 1AL3 062 
(Superseded by) 
DM4631AL3153 


262-B 
263-B 


11000 


9-5 


74322021 ** 


DM463 1PF3256 


745-C 


11000 


9-5, 9-6 



B. CALIBRATION PROCEDURES 

1. Mount the pump securely with appropriate 
adapters. The drive shaft bearing must be 
lubricated during test. An effective means 
of lubrication can be arranged by allowing 
all of the pump return oil to flow over the 
front face of the drive shaft bearing and 
then drain back to the tank thru the test 
bench bed (Fig. 9-1 ). 

NOTE: Firing order is 1-5-3-6-2-4 for 6 
cylinder engines; 1-3-4-2 for 4 cylinder 
engines. 

Leave injection line nuts at the nozzles 
loose. Install transfer pump inlet con- 
nector (No. 19971) and fuel inlet line. 

NOTE: Inlet connector No. 19971 is the only 
one to be used; use of other connectors could 
cause rotor seizure. Install transfer pump 
pressure gauge connector (No. 20012) and 
fuel line to the pressure gauge connector (No. 
20012) and fuel line to the pressure gauge with 
a shut-off valve close to the pump. Install the 
advance test window(No. 19918) in place of 
the timing line cover on the housing. 



RETURN OIL 




FIG. 9-1 



2. Pump rotation is clockwise. Rotation is 
determined as viewed from drive end of 
pump. 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 
SERVICE MANUAL 9 i 

FORM 73112988 



(Revised January 1981) 



Fuel Injection Pump References, Calibration Procedures and Data 



LOW IDLE SCREW 




TRANSFER ' 
PRESSURE' 
ADJUSTMENTS 



FIG. 9-2 



3. If the pump is equipped with an Electric 
Shut-off device, energize the solenoid be- 
fore starting the test stand. Start stand at 
lowest speed. Move pump throttle lever to 
"full-load" position. When transfer pump 
is primed, allow fuel to bleed for several 
seconds from the loosened injection line 
nuts at the nozzles. Tighten line nuts 
securely. 



WARNING 



Wear safety glasses with side shields 
or goggles when using compressed air 
for cleaning to reduce the danger of 
personal injury from flying particles. 
Limit the pressure to 2.068 bar (30 
psi) according to local or national. 
requirements. 



4. Operate pump at 500 rpm (wide open 
throttle) for 10 minutes. Dry pump off 
completely with compressed air. Observe 
for leaks and correct as necessary. Back 
out the high idle adjusting screw and 
torque screw (if equipped). 

NOTE: The inlet to the transfer pump must 
never be pressurized in excess of . 689 bar 
(10 psi) during bench testing. 



5. Vacuum Check: Close valve in fuel supply 
line - At 2 00 rpm transfer pump must be 
capable of creating vacuum of at least 457 
mm (I8")hg. If it does not, check for air 
leaks on suction side or malfunction of 
transfer pump components. 

6. Fill graduates to bleed air from test stand 
and to wet graduates. 

7. The return oil is measured by directing the 
return oil line into an appropriate cali- 
brated graduate for the proper time and 
pump speed and comparing the results with 
the specification. 

IMPORTANT: Since this oil flow is used to 
lubricate the drive shaft bearing, it must 
be returned to its original location immedi- 
ately upon completion of the above check. 

NOTE: Refer to CALIBRATION DATA for 
correct sequence of test stand adjustments. 

8. Operate at the specified speeds with wide 
open throttle and observe transfer pump 
pressure. Adjust pressure regulating 
spring plug to raise or lower transfer pump 
pressure. 

NOTE: Under no circumstances should 8.963 
bar (130 psi) be exceeded. To adjust pressure, 
remove the line to the transfer pump inlet 
connector and use a hex key wrench to adjust 
the plug. Clockwise adjustment increases 
pressure. Do not over-adjust. Re-install fuel 
inlet line after adjustment. 

NOTE: Transfer pump pressure gauge must 
be isolated by the shut-off valve at the in- 
jection pump when checking fuel delivery and 
advance movement. 

9. Check for minimum delivery at cranking 
speed. 

10. Operate at high idle speed and adjust high 
idle screw to obtain the specified delivery. 
Recheck transfer pump pressure upon com- 
pletion of this adjustment. 

11. Adjust the low idle screw to the correct 
low idle delivery. 

12. Automatic Advance: Check the cam position 
at specified points in the speed range. Ad- 
just trimmer screw, as required, to obtain 
proper advance operation. Each line on the 
advance g a uge (No. 19918) equals two pump 
degrees. After setting the advance, check 
to see that the cam returns to its inital posi- 
tion at rpm. Recheck transfer pump pres- 
sure after setting advance and correct if 
necessary. 



( 



c 



c 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 
SERVICE MANUAL 9-2 (Revised January 1979) 

FORM 73112988 



Fuel Injection Pump References, Calibration Procedures and Data 



c 



13. Record fuel delivery at check points 
shown in CALIBRATION DATA. ROLLER 
SETTINGS SHOULD NOT BE READJUSTED 
ON TEST BENCH. Experience has proven 
that micrometer and dial indicator settings 
provide more consistent, accurate results 
in performance. Variations in test bench 
drives, instrumentation, nozzles, lines 
and fuels in different areas sometimes re- 
sult in nonconforming flow readings. 

14. While operating at full-load governed 
speed, set torque screw (if employed) to 
specified delivery. Recheck the transfer 
pump pressure upon completion of this 
adjustment. 

15. Recheck delivery at lowest speed check- 
point. 

16. Check governor cut-off specified speed. 

17. Check Electric Shut-off (if equipped) at 
speeds indicated. 

18. Remove the pump from the test stand and 
assemble all sealing wires. Pump is now 
ready for installation to engine. 

C. PROCEDURE EXAMPLE 

To illustrate the use of CALIBRATION DATA, 
pump number 74321973 will be used as an 
example. The pump carries the manufacturer's 
part number DM463 1AL3 153. It is used on 
262-B, 263-B, 11000 Mark II engine. When 
the pump is rebuilt, it is to be set at the 
specifications given. The engine, with the 
pump properly calibrated, should have a high 
idle speed of 2280 -- 2340 rpm, a low idle 



speed of 600 -- 700 rpm, and should develop 
a full load horse power at 2100 rpm. A 
roller-to-roller setting of 49.911 - .038 mm 
(1.965 - .0015") should make the pump 
deliver 71 — 74 cc/500 strokes at 600 rpm 
on the test stand. At the same time, the 
transfer pump should be producing a pres- 
sure of 5.86 -- 6.205 bar (85 -- 90 psi) at 
1050 rpm. Check the pump for minimum 
rate of flow at 75 rpm on the test stand. If 
it does not deliver a minimum of 44 cc in 
500 strokes and if transfer pump pressure is 
not at least . 551 bar (8 psi) parts are worn 
excessively and do not have the proper 
tolerances. Next, set the torque screw to 
deliver the specified amount of fuel at the 
specified speed; in this case the pump should 
deliver 60 -- 62 cc/500 strokes at 1050 rpm. 
Again, check the transfer pump pressure. 

If the pump incorporates an automatic ad- 
vance mechanism, either load or speed, 
adjust the trimmer screw or shims to 
achieve the correct cam positions at the 
specified speeds or loads. 

Pump and governor specifications show that 
this pump has 7 -- 10% regulation, and that 
it is to be timed to start injection when the 
#1 engine piston is at 14° before top dead 
center. When mechanically timing the pump, 
etch the timing mark on the rotor according 
to the procedure outlined. (See page 11-2). 

For proper testing and adjusting of pumps, 
it is mandatory that the test stand and its 
accessories be in good condition. The 
following check list will provide a guide for 
proper maintenance of the test stand. 



c 



D. ANEROID ADJUSTMENTS 

1. Operate pump at 



2. Pressurize the aneroid, and check shut-off lever response. 



Lever should lift off screw at 



1000 rpm (745-C) 
900 rpm (645-B) 



102-152 mm (4"-6")Hg (745-C) 
254-305 mm (10"-12»)Hg (645-B) 



If lever lift-off requires less than minumum Hg, shorten 
operating rod; if more than maximum Hg, lengthen rod. 

3. While viewing end plate, position aneroid so that inlet 

fitting is at - 12 o'clock (745-C) 

10 o'clock (645-B) 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 

SERVICE MANUAL 9-3 (Revised February 1 989) 

FORM 73112988 



E. CALIBRATION DATA (Roosa-Master 


-DM) 




















F/A PUMP NO. 
Mfr. Pump No. 


74008318 
DM4629RH3260 


74008322 
DM4629RH3259 


74008551 
DM4629RP3278 


74008552 
DM4629RP3279 


TEST NOZZLE 
Nozzle Holder 
Pressure-bar 
(psi) 


12SD12 

BKB50SD 

172.4 

(2500) 










































* 








ANEROID 


(Refer to page 9-3 for Aneroid Adjust 


ment) 




APPLICATION 


Wh. Loader 
605-B 


Wh. Loader 
545-B 


Wh. Loader 
545-B 


Wh. Loader 
605-B 


ENGINE 
High Idle rpm 
Low Idle rpm 
Full Load rpm 
Timing B.T.D.C. 


2900 MK II 

2500-2640 

750-800 

2400 
20°Static 


















w±yi 








































ADJUSTMENTS 
Roller-Roller Dim. 

Timing Mark Angle 
Gov. Linkage Gap 

Gov. Regulation 


49.58 ±. 038mm 
(1.952 ±.0015") 

351.5° 

3.175 - 3.683mm 

(.125 - .145") 

7-10% 


49.53 i .038mm 
(1.950 ± .0015") 








49.58 + .038mm 
H 9^2 + 001 k»\ 
























* 


























TRANSFER PUMP 
Pressure-bar 

(psi) 
@ rpm(full throttle) 


5.86-6.55 

(85-95) 

1200 


























* 


* 














FLOW CHECK (R-R) 
cc @ 500 Strokes 
@ rpm(full throttle) 
Max. Variation 
Between Cylinders 


38-41 
800 


OC OQ 








3R-41 














• 


- 


- 




FLOW CHECK (Min.) 
cc @ 500 Strokes 
@ rpm(full throttle) 
@ Trans.Pump Press-bar 
(psi) 


22 

75 

.69 min. 

(10) 












41 






za 
































HIGH IDLE (Set) 
cc @ 500 Strokes 
@ rpm(full throttle) 
Max. Variation 
Between Cylinders 


8-10 
1320 


























- 


- 


- 




TORQUE SCREW (Set) 
cc @ 500 Strokes 
@ rpm(full throttle) 
Max. Variation 
Between Cylinders 


30-32 
1200 










Qft QO 




AO-OVJ 






OU-OZ 






- 






LOW IDLE (Set) 
cc @ 500 Strokes 
@rpm 


8-10 
350 


































AUTO. SPEED ADV. 

Pump 

Engine 

@rpm 


1° 

2° 

200 


6° 
12° 
600.700 


8° 
16° 
by 1000 










































































GOV. CUT-OFF(Check) 
cc @ 500 Strokes 
@ rpm(full throttle) 


10 max 






















* 



















( 



c 



c 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 
SERVICE MANUAL 9-4 (Revised June 1979) 

FORM 73112988 



E. CALIBRATION DATA (Roosa-Master-DM) 



F/A PUMP NO. 
Mfr. Pump No. 



74321924 
DM4631FB3129 



74321973 
DM4631AL3153 



74322021 
DM4631PF3256 



TEST NOZZLE 
Nozzle Holder 
Pressure-bar 
(psi) 



8S2C 

BKB50SD 

172.4 

(2500) 



8S2C 

BKB50SD 

172.4 

(2500) 



12SD12 



8S2C 

BKB50SD 

172.4 

(2500) 



ANEROID 



(Refer to page 9-3 for Aneroid Adjustments) 



APPLICATION 



Wh. Loader 
745-C 



Scrapers 
262-B, 263-B 



Wh. Loader 
745-C 



ENGINE 
High Idle rpm 
Low Idle rpm 
Full Load rpm 
Timing B.T.D.C. 



11000 MK II 

2350-2450 

750-800 

2200 
14°Static 



11000 MK II 

2280-2340 

600-700 

2100 
14°Static 



68 5T 



11000 MK II 

2350-2450 

750-800 

2200 
14°Static 



ADJUSTMENTS 
Roller-Roller Dim. 

Timing Mark Angle 
Gov. Linkage Gap 

Gov. Regulation 



50.241 ± .038mm 
(1.978 ± .0015") 

348.50° 

3.175 - 3.683mm 

(.125 - .145") 

7-10% 



49.911 ± .038mm 
(1.965 ±.0015") 

350° 

3.175 - 3.683mm 

(.125 - .145") 

7-10% 



49.96 ±.038 mm 
(1.967 ±.0015") 



50.241 ± .038mm 
(1.978 ± .0015") 

348.50° 

3.175-3683mm 

(.125-.145") 

7-10% 



TRANSFER PUMP 
Pressure-bar 

(psi) 
@ rpm(fuli throttle) 



6.55 -6.895 

(95-100) 

915 



5.86-6.205 

(85-90) 

1050 



5.86-6.205 

(85-90) 

915 



FLOW CHECK (R-R) 
cc @ 500 Strokes 
@ rpm(full throttle) 
Max. Variation 
Between Cylinders 



84-87 
915 



71-74 
600 



60-64 
750 



84-87 
915 



FLOW CHECK (Min.) 
cc @ 500 Strokes 
@ rpm(fuli throttle) 
@ Trans.Pump Press-bar 
(psi) 



52.5 

75 

.6895 min. 

(10) 



44 

75 

.5516 min. 

(8) 



40 



52.5 

75 

.6895 min. 

(10) 



HIGH IDLE (Set) 
cc @ 500 Strokes 
@ rpm(full throttle) 
Max. Variation 
Between Cylinders 



12-14 
1212 



22-28 
1150 



12-14 
1212 



TORQUE SCREW (Set) 
cc @ 500 Strokes 
@ rpm(fuil throttle) 
Max. Variation 
Between Cylinders 



73-77 
915 



60-62 
1050 

2.5 



54-56 



73-77 
915 



LOW IDLE (Set) 
cc @ 500 Strokes 
@rpm 



14-16 
412 



25-30 
360 



12-14 



14-16 
412 



AUTO. SPEED ADV. 

Pump 

Engine 

@rpm 



2° 
200400 



10° 
20° 
750-700 by 875 



If 



22' 



11° 
22° 
200-3001500-550 by 650 



9°Set 
18° 



250 



550 



by 800 



2° 
200400 



10° 
20° 
750-800|by 



11° 
22° 

8751 



GOV. CUT-OFF(Check) 
cc @ 500 Strokes 
@ rpm(full throttle) 



5 
1237 



5 max. 
1225 



10 max. 



5 
1237 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 

SERVICE MANUAL 9-5 (Revised January 1 981) 

FORM 73112988 



E. CALIBRATION DATA (Roosa-Master-DM) 



F/A PUMP NO. 
Mfr. Pump No. 



74036268 
DM4629RH3277 



74321756 
DM4631AJ3069 



74322021 
DM463 IP F3256 



( 



TEST NOZZLE 
Nozzle Holder 
Pressure-bar 
(psi) 



12SD12 

BKB50SD 

172.4 

(2500) 



12SD12 

BKB50SD 

172 . 4 

(2500) 



12SD12 



12SD12 
BKB50SD 
172.4 
( 2 5QQ ) 



ANEROID 



(Refer to page 9-3 for Aneroid Adjustment) 



APPLICATION 



ENGINE 
High Idle rpm 
Low Idle rpm 
Full Load rpm 
Timing B.T.D.C. 



Wh. Loader 
645-B 

3500 MK II 

2360-2480 

750-800 

2200 
16°Static 



Graders 
100-C, 150-C 

11000 MKII, 685T 

1950-2020 

600-700 

1800 

14°Static 



685T 



Wh. Loader 
745C 

685T 

2350-2450 

750-800 

2200 

140 Static 



ADJUSTMENTS 
Roller-Roller Dim. 

Timing Mark Angle 
Gov. Linkage Gap 

Gov. Regulation 



50.11 ±.038mm 
(1.973 +.0015") 

351° 

3.175 - 3.683mm 

(.125 - .145") 

7-10% 



49 . 7±. 038mm 
(1.95 7±.0015") 

351° 

3 . 175-3 . 683mm 

( . 125-.145") 

12% 



49.7 ± .038mm 
(1.957 + .0015 M ) 



12% 



50.24 +.03 8mm 
(1.978 ±.0015") 

348.5° 

3. 175-3. 683mm 

( .125-. 145") 

7-10% 



TRANSFER PUMP 
Pressure-bar 

(psi) 
@ rpm(full throttle) 



5.86-6.55 

(85-95) 

1100 



5.516-6.205 

(80-90) 

900 



5.86-6.205 
(85-90) 
915 



FLOW CHECK (R-R) 
cc @ 500 Strokes 
@ rpm(full throttle) 
Max. Variation 
Between Cylinders 



61-64 
800 



50-53 
800 



50-53 
800 



84-87 
915 



C 



FLOW CHECK (Min.) 
cc @ 500 Strokes 
@ rpm(full throttle) 
@ Trans.Pump Press-bar 
(psi) 



31 

75 

.5516 min. 

(8) 



50 

75 

69 min, 

(10) 



50 



.69 min. 
(10) 



50 
75 
,6895 min, 
(10) 



HIGH IDLE (Set) 
cc @ 500 Strokes 
@ rpm(full throttle) 
Max. Variation 
Between Cylinders 



10-12 
1210 



10-12 
1010 



1010 



12-14 
1212 



TORQUE SCREW (Set) 
cc @ 500 Strokes 
@ rpm(full throttle) 
Max. Variation 
Between Cylinders 



50-52 
1100 



47-49 
900 



47-49 



73-77 
915 

11 



LOW IDLE (Set) 
cc @ 500 Strokes 
@rpm 



10-12 
350 



10-14 
200 



10-14 



14-16 
412 



AUTO. SPEED ADV. 

Pump 

Engine 

@rpm 



1° 
2° 



8° 10° 
16° 20° 
2504501725-775 by 1000 



1° 
2° 
200-300 



9° 
18° 
500-550fcby 



Full 

Full 

800 



Full 1° 

Full 2° 

by 800 250 



10° 
20° 
825 



Full 
Full 
by 900 



GOV. CUT-OFF(Check) 
cc @ 500 Strokes 
@ rpm(full throttle) 



10 max 
1235 



10 max. 
1035 



1035 



10 max, 
1237 



c 



Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 

SERVICE MANUAL 9-6 (Revised February 1 989) 

FORM 73112988 ' 



E. CALIBRATION DATA (Roosa-Master-DM) 



F/A PUMP NO. 
Mfr. Pump No. 


r 


r4ft3K»97 


74321882 


> 






DM4629RH3230 


DM4631AJ3117 






TEST NOZZLE 
Nozzle Holder 
Pressure-bar 
(psi) 


12SD12 

BKB50SD 

172.4 

(2500) 


12SD12 

BKB50SD 

172.4 

(2500) 


12SD12 










ANEROID 


(Refer to page 9-3 for Aneroid Adjustments) 


APPLICATION 


Wh. Loader 
645-B 


Grader 
200-C 








* 


ENGINE 
High Idle rpm 
Low Idle rpm 
Full Load rpm 
Timing B.T.D.C. 


3500 MK II 

2360-2480 

750-800 

2200 
16° Static 


11000 MK II 

1950-2020 

600-700 

1800 
14° Static 
















ADJUSTMENTS 
Roller-Roller Dim. 

Timing Mark Angle 
Gov. Linkage Gap 

Gov. Reguation 


50.11 ± .038mm 
(1.973 ± .0015") 

349.5° 

3.175-3683mm 

(.125-.145") 

7-10% 


49.87±. 038mm 
1. 965±.0015") 

350° 

3. 175-3. 683mm 

(.125-. 165") 

7-12% 


















TRANSFER PUMP 
Pressure-bar 

(psi) 
@ rpm(full throttle) 


5.86-6.55 

(85-95) 

1100 


5.516-6.205 

(80-90) 

900 












FLOW CHECK (R-R) 
cc @ 500 Strokes 
@ rpm(full throttle) 
Max. Variation 
Between Cylinders 


61-64 
800 

8 


58-62 
700 


58-62 
700 




FLOW CHECK (Min.) 
cc @ 500 Strokes 
@ rpm(full throttle) 
@ Trans.Pump Press-bar 

(psi; 


31 

75 

.5516 min. 

(10) 


37.5 

75 

.6895 min. 

(10) 


37.5 








^ 


HIGH IDLE (Set) 
cc @ 500 Strokes 
@ rpm(full throttle) 
Max. Variation 
Between Cylinders 


10-12 
1210 

3 


10-12 
1010 


10-12 




- 


TORQUE SCREW (Set) 
cc @ 500 Strokes 
@ rpm(full throttle) 
Max. Variation 
Between Cylinders 


50-52 
1100 


55-57 
900 


55-57 






LOW IDLE (Set) 
cc @ 500 Strokes 
@rpm 


10-12 
350 


12-14 
200 










AUTO. SPEED ADV. 

Pump 

Engine 

@>rpm 


1° 
2° 
250450 


8° 
16° 

725-775 


10° 
20° 
by 1000 


1° 
2° 


9° 
18° 


11° 

22° 

by800 










25 0min 55U 

1 




GOV. CUT-OFF(Check) 
cc @ 500 Strokes 
@ rpm(full throttle) 


10 max. 


10 max. 
ins* 























Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel. 
SERVICE MANUAL 9-7 (Revised February 1 989) 

FORM 73112988 



( 



c 



TOPIC 10 INSTALLATION 



C 



TIMING LINES 



C 



DISTRIBUTOR ROTOR 



CAM 




FIG. 10.1 



DANGER 



Extinguish all smoking materials and 
open flames before working around 
diesel fuel. 



INSTALLING THE PUMP 

A. Remove timing line cover. 

B. Turn pump drive shaft in the direction 
of pump rotation until the timing line on the 
Distributor rotor registers with the line on 
the cam O.D. (Fig. 10.1) 



I 



C . Check TEST STAND DATA ( Topic 9) 
for proper timing position of crankshaft . 

D . Slide the pump into position over the 
mounting studs . Assemble washers and the 
mounting stud nuts and tighten . 

E . Install the pump drive gear to the hub 
or drive shaft . Refer to the engine manual . 
Back off the engine at least 1/2 revolution 
and bar it in the direction of rotation to the 
proper timing mark . Recheck line marks 
in the pump and correct if necessary . Re- 
peat procedure to insure proper timing. In- 
stall timing line cover . 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

10-1 



Installation 



F . Remove caps on high pressure lines . 
Connect the lines to their respective dis- 
charge fittings and tighten to specified 
torque .(Refer to engine manual .) Connect 
throttle and shut-off linkage and electrical 
connections if used . Assemble and tighten 
fuel return line . Open bleed screw on 
secondary filter, and operate hand primer 
(if equipped and filter is after hand primer) 
or allow fuel to flow from tank until all air 



is dispelled from filter. 

NOTE: Do not open filter bleed if hand 
primer is after filter. Close bleed screw. 
Continue hand priming until a quantity of 
fuel flows "air-free" at pump inlet line . 
Fasten the inlet to the pump. This pro- 
cedure should also be followed without fail 
after every filter change . Refer to 
Operation and Maintenance Instruction 
Manual for starting instructions before 
starting engine . 



c 



c 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

10-2 



TOPIC 11 GENERAL DATA 



GENERAL DATA 



( 



c 



c 



The Model DM Fuel injection Pump operates 
with all types of combustion chambers on 2 
or 4 stroke cycle engines. 

TRANSFER PUMP OPERATIONAL DATA 

Maximum permissible transfer pump 
pressure - 130 psi. 



Transfer pump lift for fully primed injection 
pump at 400 engine RPM (minimum) - 18 in. 
of mercury. 

DIMENSIONAL DATA 

Weight of basic pump, regardless of number 
of cylinders served - approximately 14 lbs. 



VENDOR 


Fiat- All is 


PART NO. 


Part No. 


13301 


75294932 


13337 


75300888 


13375 


75300894 


13379 


75294818 


13383 


75294815 


14067 


75294819 


14490 


75294822 


14725 


75294820 


16349 


75300910 


18031 


75294880 


18332 


75300912 


18914 


75294884 


19918 


75300887 


19924 


Part of 75300891 


19927 


75300891 


19928 


Part of 75300893 


19930 


75300893 


19965 


75300895 


19969 


75294821 


16094 


Part of 75294821 


16099 


Part of 75294821 


19966 


Part of 75294821 


19967 


Part of 75294821 


19971 


75300896 


20012 


75300897 


20029 


75300898 


20043 


75300899 


20044 


75300901 


20045 


75300903 


20268 


75300904 


20395 


75300906 


20545 


75300909 


2 0546 


75300911 


20548 


75300914 


20549 


75300915 


20550 


75300916 


20920 


75300917 


20992 


75300918 



SERVICE TOOLS 

Service tools required to perform the various repairs 
explained in this manual are listed below. 

Order service tools from your local Fiat-Allis dealer. 

IMPORTANT: Refer to Fiat-Allis Tool Catalogs, as 
follows, for complete tool illustrations, descriptions 
and usage: 

English 73 128466 

French- 73128467 

Spanish 73 128468 

Italian 73128469 

DESCRIPTION 



Pressure regulating sleeve puller 
Snap ring pliers 
Rotor retaining ring installer 
Linkage hook wrench 
Delivery valve extractor 
Fuel shut- off adjusting tool 
Advance screw and piston plug wrench 
Fuel shut-off adjusting weight 
Snap ring pliers 
Aneroid bracket tool 
End cap gauge 

Linkage hook adjustment gauge 
Advance test window- 
Puller 

Gear hub puller 
Bracket 

Holding fixture bracket kit 
Holding fixture plate assembly 
Centrality gauge kit 
Indicator 
Bracket screws 
Sleeve 

Bracket - indicator 
Inlet connector 

Transfer pump pressure check adapter 
Holding fixture plate assembly 
Snap ring pliers 
Snap ring pliers 

Governor weight retaining clip installer 
Drive shaft seal installer 
Timing line location indicator 
Holding fixture plate assembly 
End cap wrench 
End cap wrench 
End cap plug 

Drive hub for testing pump 
Drive shaft bearing installer 
Throttle shaft retaining clip remover 

11-1 (Revised January 1981) 




T-30628 



TIMING LINE LOCATION INDICATOR (Tool No. 20395) 

DIRECTIONS 

1. Place dry distributor rotor on indicator dial with drill point reference mark on rotor 
adjacent to reference mark on dial . 

2 . Turn dial counter-clockwise to timing mark degree location indicated in TEST STAND 
DATA ( Topic 9). Read number of degrees on inner or bottom set of numbers . 

3 . Pencil mark weight retainer hub in line with point of arrow labeled "Place Timing 
Line Here". Remove the rotor and overscore pencil mark with an electric pencil or 
similar tool. 



c 



c 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

11-2 



TORQUE VALUES 



All values are given in lb. inches (kg-cm) unless circled. 



35-45 
(40-52) 35-40 

(40-46) 



DELIVERY VALVE SCREW 

•85-90 (STANDARD DELIVERY VALVE) (98- 103. 5) 

•120-125 (.250" DELIVERY VALVE) ( 138- 144) 




25-30(29-34.5) 
180-220 (207-253) 



VALVE SCREWS 



(207-253) 

•180-220 

80-90 

(92-103.5) 40-50(46-57.5) 



215-265 

(247-305) 



*CRITICAL TORQUE VALUES 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

11-3 



TROUBLESHOOTING 



PROBLEM 



PROBLEM 

MAY 

OCCUR 



CAUSE 

Numbers in "Problem" Cheek 

Chart indicate order in which 

to check possible "Causes" 

of Problem. 




CORRECTION 



( 



Transfer Pump liner locating pin in 
wrong hole for correct rotation. 



ON TEST 
STAND 

FOLLOWING 
OVERHAUL 



Plunger missing. 



Cam backwards in housing. 



Metering Valve incorrectly assembled 
to metering valve arm. 



Delivery Valve Sticking, missing or 
assembled backwards. 



Hydraulic head vent wires missing. 



Idling spring missing, or incorrect. 



13 



19 



21 



15 



24 



Re-install properly. 



Assemble new plunger. 



Reassemble cdrrectly. 



Reassemble correctly. 



Remove, clean or replace as needed. 



Install as indicated in reassembly instructions. 



Assemble as indicated in reassembly instruc- 
tions. 



FOLLOWING 

INSTALLATION 

ON 

ENGINE 



Hand primer installed backwards. 



Re-install properly. 



Seizure of Distributor Rotor. 



Check for cause of seizure. Replace hydraulic 
head and distributor rotor assembly. 



Failure of electrical shut-off. 



«2 



Remove, inspect and adjust parts. Replace parts 
as necessary. 



Fuel supply lines clogged,- restricted, 
wrong size or poorly located. 



13 



Blow out all fuel lines with filtered air. Replace if 
damaged. Remove and inspect all flexible lines. 



Air leaks on suction side of system. 



11 



Trouble-shooting the system for air leaks. See 
Supplementary Inspections in manual. 



Transfer Pump Blades worn or broken. 



12 



18 



13 



Replace. 



Delivery Valve Retainer Screw loose 
and leaking or incorrectly installed. 



25 



20 



Inspect Delivery Valve Stop seat for erosion, 
tighten Retainer Screw, or replace head and rotor 
assembly as needed. 



DURING 
OPERATION 



Transfer Pump Regulating Piston 
sticking. 



10 



13 



19 



12 



Remove piston and regulator assembly and 
inspect for burrs, corrosion or varnishes. Replace 
if necessary. 



Shut-off device at "stop" position. 



Move to "run" position. 



Plungers sticking. 



10 



21 



18 



17 



Disassemble and inspect for burrs, corrosion or 
varnishes. 



Metering Valve sticking or closed. 



14 



12 



10 



Check for governor linkage binding, foreign 
matter, burrs, missing metering valve shim, etc* 



Passage from Transfer Pump to 
Metering Valve clogged with foreign 
matter. 



11 



Disassemble and flush out Hydraulic Head. 



Tank valve closed. 



Open valve. 



Fuel too heavy at low temperature. 



Add kerosene as recommended for 0°F, -15° F 
and -30° F temperatures. 



Cranking speed too low. 



Charge or replace batteries. 



Lube oil too heavy at low temperature. 



18 



See engine manual. 



F.ngine engaged with load. 



Disengage load. 



Nozzles faulty or sticking. 



10 17 



10 



Replace or correct nozzles. 



Intake air temperature low. 



5 



F.ngine compression poor. 



17 



Pump timed incorrectly to engine. 



Kxcessive fuel leakage past plungers 
I worn or badly scored). 



15 



Filters or Inlet Strainer clogged. 



Cam. Shoes or Rollers worn. 



14 



Automatic advance faulty or not 
operating. 



Governor linkage out of adjustment or 
broken. 



Governor not operating: parts or 
linkage worn, sticking or binding, or 
incorrectly assembled. 



Maximum fuel setting too low. 



Kngine valves faulty or out of 
adjustment. 



11 



12 



Provide starting aids. See engine manual. 



10 



25 



Correct compression. See engine manual. 



22 



16 



18 



20 



24 



16 



26 



28 



16 



1 1 



11 



12 



14 



11 



13 



6 9 



10 



15 



14 



Correct timing. See engine manual. 



Replace rotor and hydraulic head assembly. 



Remove and replace clogged elements. Clean 
strainer. 



Remove and replace. 



Remove, inspect, correct and reassemble. 



Adjust governor linkage hook. 



Disassemble, inspect parts, replace if necessary 
and reassemble. 



Reset to pump specifications. 



Correct valves or valve adjustment as in engine 
manual. 



C 



Study SAFETY RULES, pages I thru III, thoroughly for the protection of personal and machine safety. 

11-4 



TROUBLE SHOOTING 



PROBLEM 



c 



c 



PROBLEM 

MAY 

OCCUR 


CAUSE 

Numbers in "Problem" Check 

Chart indicate order in which 

to check possible "Causes" 

of Problem. 




/ Zf /s> / / /£&/ /? A / A 
/ /? As A A //§/ /^ A /£/ 

/& Ay Af / A ff A?*/ ^'Af* / / £ / 

/Jfttf /*/{/$ iff M*/ correction 

/& /$$/& / £ A s? A£&A */& /«?/ $/ 

f ijf4v*f/fffliffji/t/ 
*M££#/$M/$/*g*/$/ 

/<*>' Av yo'AvA- A °/*/ v v / 




Water in fuel. 










2 


5 


1 


23 






Drain fuel system and pump housing, provide 
new fuel, prime system. 




Return oil line or fittings restricted. 








29 


4 


23 


19 


8 






Remove line, blow clean with filtered air and 
reassemble. Replace if damaged. 




Engine rotation wrong. 


4 




















Check engine rotations See engine manual. 




Air intake restricted. 










3 






26 


2 




Check. See engine manual. 




Wrong Governor spring. 












17 




27 






Remove and replace with proper spring as in 
pump specifications. 


DURING 
OPERATION 


Pump housing not full of fuel. 












7 


2 








Operate engine for approximately b- minutes 
until pump fills with fuel. 




Low cetane fuel. 






13 


1 1 




6 


14 


20 


8 




Provide fuel per engine specifications. 




Fuel lines incorrect, leaking or 
connected to wrong cylinders. 






6 






1 




28 






Relocate fuel lines for correct engine firing 
sequence. 




Tang Drive excessively worn. 












22 




19 




5 


Remove and install new head and rotor assembly 
and drive shaft as necessary. 




Governor sleeve binding on drive shaft. 












16 










Remove, inspect for burrs, dirt, etc. Correct and 
reassemble. 




Shut-off device interfering with Gover- 
nor linkage. 






8 


15 








2 






Check and adjust governor linkage dimension. 




Governor high-idle adjustment incor- 
rect. 
















3 






Adjust to pump specifications. 




Torque Screw incorrectly adjusted. 




5 


9 


23 








22 


11 




Adjust' to specification. 




Throttle Arm travel not sufficient. 






4 










1 






Check installation and adjust throttle linkage. 




Rotor excessively worn. 




12 


16 


27 














Replace hydraulic head and rotor assembly. 




Maximum fuel setting too high. 


















10 




Reset to pump specifications. 




Engine overheating. 










5 








3 




Correct as in engine manual. 




Exceeding rated load. 


















1 




Reduce load on engine. 




Engine cold. 








30 












1 


Check thermostats or shutter controls, warm to 
operating temperature. See engine manual. 




Lube oil pumping past valve guides or 
piston rings in engine. 




















6 


Correct as in engine manual. 




Excess lube oil in engine air cleaner. 




















2 


Correct as in engine manual. 



e 



Study SAFETY RULES, pages I thru HI, thoroughly for the protection of personal and machine safety. 

11-5 



c 



c 



c 



( 



c 



c 



TOPIC 12 
PARTS CATALOG 

INSTRUCTIONS FOR ORDERING PARTS 



At the time this parts catalog was published the listed part numbers 
were current. It is our policy to constantly improve our machines and 
therefore, part numbers and design may change. When ordering parts, 
verify part numbers through your dealer's parts catalog which is up 
to date with all latest part numbers. 



Order parts from the dealer covering the local territory. 

ALWAYS GIVE THE MODEL AND SERIAL NUMBER OF INJECTION PUMP. 

To obtain parts promptly, give part name and part number. 

Give post office address, town, county and state where parts are to be shipped. 
Also specify whether material is to be shipped by freight, express or parcel post. 

Confirm all telephone or telegraph order in writing. 

No credit will be allowed on parts unless that are returned to the dealer from 
whom they were purchased; from there they will be returned, at the customer's 
expense, to the factory for inspection. 

Unless claims for shortages or errors are made immediately upon receipt of 
goods, they will not be considered. 

When broken goods are received, a full description of the damage should be 
made by the carrier agent on the freight bill. If this description is insisted 
upon, full damage can always be collected from the transportation company. 

No responsibility is assumed for delay or damage to merchandise while in 
transit. Our responsibility ceases upon delivery of shipment to the transpor- 
tation company from whom a receipt is received showing that shipment was 
in good condition when delivered to them; therefore, claims (if any) should be 
filed with the transportation company. 

The right is reserved to change the construction or material of any parts 
where it seems desirable to do so without incurring the obligation of installing 
sudi changes on units already delivered. 

(Specifications and design subject to change without notice) 



12-1 



t 



H 
i 

00 

o 
o 




Fig. 11.3 



INJECTION PUMP PARTS 



r*\ 



/"""""V 



( 



c 



c 



USAGE 
ITEM 

1 
2 
3 

4 
5 
6 
7 
8 

9 
10 

11 
13 
14 
15 
16 
18 
19 
20 
21 
22 
23 
24 
26 

27 
28 



29 
30 
31 
32 
33 
34 
35 
36 
37 
38 
39 
40 
41 
42 
43 
44 
45 
46 
47 
48 
49 
50 
51 
52 



:262B,263B 

PART NO. 

74321973 

70910345 

74061132 

74062193 

70925995 

74061141 

74061142 

74061135 

74061134 

74062187 

74061570 
74062050 
74062183 
74051559 
74049532 
74052915 
74061670 
74061709 
74061703 
74048627 
74049533 
74048635 
74061168 

74061781 
74048624 



74059171 

74061704 
74053267 

70906957 
74053266 
74055293 
74051807 
74048630 
74061206 
74059170 

74061744 
74051412 
74051413 
74054594 
74056486 
74369478 
74056484 
74048645 
74369507 

74061716 
74369507 
74048645 
74053375 
74369878 



INJECTION PUMP PARTS 
Motor Scraper (Model 11000 MKH Engines) 
QTY. DESCRIPTION 

1 PUMP ASSY. , injection (Includes items 1 thru 155) 

1 NUT, hub retaining 

1 WASHER, hub retaining 

1 HUB, gear 

1 RING, retaining 

1 WASHER, drive shaft spring 

1 BEARING, ball 

1 PIN, spring, drive shaft 
RING, bearing shoulder 
SHAFT, drive 
RING, seal retaining (Not required) 

□ SEAL, drive shaft 
SCREW, head locking 
SEAL, pump flange 
CLIP, shaft retainer 
LEVER, throttle shaft 
SHIM, metering valve 
SPRING, metering valve 
VALVE, metering 
ARM ASSY. , metering valve 
GUIDE, idling spring 
SPRING, idling 
RETAINER, spring 
ARM, governor 

SPRING, governor control (Black-Brown) 

SPRING, governor linkage 

HOOK ASSY. , governor linkage (Includes items 29, 
30, 37, 38) 

LINK ASSY. , adjusting 

HOOK, governor linkage 
3 WASHER, plain 

3 LOCKWASHER, cover screw 

3 SCREW, cover 

CONNECTOR ASSY. , return line 

COVER, governor control 

□ GASKET, governor cover 
WASHER, adjusting link 
SCREW, adjusting link 
SCREW, throttle lever spring 
RETAINER, throttle lever spring 
SPRING, throttle lever 
LEVER ASSY. , throttle 
ARM, adjusting spacer 
SCREW, spacer 
SPACER, throttle lever 
SCREW, low idle adjusting 
NUT, low idle adjusting screw 
SHAFT ASSY. , throttle 
NUT, high idle adjusting screw 
SCREW, high idle adjusting 

2 □ WASHER, throttle shaft seal 
2 □ SEAL, throttle shaft 



(Continued) 
12-3 



Revised January 1981) 



INJECTION PUMP PARTS (Continued) 
ITEM PART NO. QTY. DESCRIPTION 



53 
54 
55 
56 
57 
58 
59 
60 
61 
62 
63 
64 
65 
66 
67 
68 

69 

70 

71 

72 

73 

74 

75 

76 

76A 

77 

88 

89 

90 

91 

92 

93 

94 

95 

96 

97 

99 

100 

101 

102 

103 

104 

105 

106 

107 

108 

109 

110 



112 
113 
114 



74050910 
74048642 
74048636 
74369429 
74369428 
74061192 
74048603 
74048604 
74059271 
74062184 
74061170 

74054589 
74059066 
74054585 
74059067 
74369595 
74061130 
74051365 
74061131 
74051378 
74048650 
74369878 
74054582 
74054583 
74052917 
74061715 
74054583 
74369878 
74062194 
74061127 
74061169 
74061873 
74054589 
74054593 
74054591 
74062182 
74061128 
74059064 
74062192 
74061852 
74061148 
74061149 
74061150 
74055970 
74055890 
74055969 
74369436 
74061590 
74061509 
74061157 
74061156 
74061155 
74061154 



2 DSEAL, pivot shaft 
2 NUT, pivot shaft 

SHAFT, governor arm pivot 

SCREW, name plate 

PLATE, name 

SCREW, timing line cover 

COVER, timing line 
□ GASKET, timing line cover 

PLUG, piston (spring) 

HOUSING ASSY. , pump 
DSEAL, advance piston hole plug 
DSEAL, advance piston hole plug 

PIN, advance 
DSEAL, advance screw hole plug 

PLUG, advance screw hole 
DSEAL, head locating screw 

SCREW, head locating 
DSEAL, head locating screw 

PLUG, head locating screw 

STUD, guide 
D WASHER, guide stud 
DSEAL, torque screw 

SCREW, torque 

NUT, torque screw 

CAP, cover, adjusting screw 

SHAFT, shut -off 

NUT, advance adjusting screw 
DSEAL, advance adjusting screw 

PLUG, piston hole (power) 

VALVE, reed 

SCREW, reed valve 

SEAL, advance piston hole 
D SEAL, advance piston hole 

SCREW, advance adjusting 

GUIDE, advance adjusting screw 

SPRING, outer advance 

RING, advance piston 
DSEAL, piston ring 

PISTON, advance 

SLEEVE, governor thrust- 

WASHER, governor thrust sleeve 

WEIGHT, governor 

RETAINER ASSY. , governor 

SCREW, leaf spring 

2 SPRING, leaf 

1 SCREW, leaf spring 

4 ROLLER, cam 

4 SHOE, cam roller (-. 38lmm)(-. 015") 

4 SHOE, cam roller (-. 254mm)(-. 010") 

4 SHOE, cam roller (-. 508mm)(-. 020") 

6 D CUSHION 

3 RETAINER, cushion 

6 DRING, retaining "E" clip 



( 



c 



Use as 
required 



c 



SERVICE MANUAL 
FORM 73112988 



(Continued) 
12-4 



(Revised January 1979) 



( 



c 



rEM 


PART NO. 


QT 


116 


74062185 


1 


117 


74061188 


1 


118 


74061161 


1 


119 


74061160 


1 


120 


74062051 


1 


121 


74369444 


1 


122 


74062195 


1 


123 


74061661 


1 


124 


74061663 


2 


125 


74061195 


6 


126 


74061187 


1 


127 


74061159 


1 


128 




1 


129 


74061172 


1 


130 


74059733 


4 


131 


74055958 


2 


132 


74061665 


1 


133 


74061162 


1 


134 


74061163 


1 


135 


74061174 


1 


136 


74061164 


1 


137 


74061165 


1 


138 


74061175 


1 


139 


74055960 


1 


140 


74061666 


1 


141 


74061662 


1 


142 


74061664 


1 


143 


74061660 


1 


144 


74053829 


2 


145 


74060067 


3 


146 


74062188 


1 


147 


70912739 


1 


148 


74051383 


2 


149 


74061205 


1 


150 


74049437 


2 


151 


74060670 


1 


152 


74369502 


2 


153 


74060214 




154 


74053332 




155 


74053378 




- 


74061643 




156 


74061643 





INJECTION PUMP PARTS (Continued) 
Y. DESCRIPTION 

VALVE, delivery 
SPRING, delivery valves 
STOP, delivery valve 
SCREW, delivery valve 
RING, cam 

□ SEAL, hydraulic head 

HEAD ASSY. (Includes rotor, plunger, 3 screws, 
1 vent wire and item 125) 

□ SEAL, transfer pump 
RETAINER, rotor 
CONNECTOR, fuel line 
SCREW, locking plate 
PLATE, locking 

WASHER, locking plate (Not required) 

LINER, transfer pump 

BLADE, transfer pump 

SPRING, transfer pump blade 

RING, inner locating 

ROLLPIN 

□ SEAL, regulating piston 
REGULATOR ASSY. , transfer pump 

□ SEAL, inlet filter screen 
PISTON, regulating 
SPRING, regulating 

PLUG ASSY. , end plate adjustment 

RING, screen retainer 

SCREEN, inlet filter 

PLATE, transfer pump pressure 

CAP, transfer pump end 

NUT, lock terminal contact 

WASHER, terminal contact 

STRAP, terminal ground 

LOCKWASHER, terminal contact 

WASHER, terminal insulating 

LOCKWASHER, cover screw 

NUT, terminal contact 

COIL ASSY. , shut- off (24V. E. T.S. O. )(Includes 

solenoid which is not serviced separately and items 

144, 145,148, 150 and 152 thru 155) 
TUBE 

SLEEVE, coil arm spring 
SPRING 

ARM ASSY. , solenoid 
GASKET KIT, pump 
GASKET KIT, pump (Includes items 11,36,51,52,53,60, 

60,63,64,66,68,70,73,74,89,100,112,114,121,123,134 

and 136 )(Suf fie lent quantity for complete overhaul) 

D Components of item 156 



e 



SERVICE MANUAL 
FORM 73112988 



12-5 



(Revised January 1981) 




■ l - / nm\rm 



135 136 137 



-i. 



Ml tt2 



SERVICE MANUAL 
FORM 73112988 



INJECTION PUMP PARTS 
12-6 



T-80630 



(Revised January 1979) 



INJECTION PUMP PARTS 



USAGE: 545-B, 605-B Wheel Loaders (Model 2900 MKII Engine, 649T Engine) 



c 



c 



ITEM 



1 
2 
3 

4 

5 

6 

7 

8 

9 

10 

11 

13 

15 
16 
17 
18 
19 
20 
21 
22 
23 
24 
26 
27 
28 



29 
30 
31 
32 
33 
34 
35 
36 
37 
38 
39 
40 
41 
42 
43 
44 
45 
46 
47 



PART NO. 

74008322 

74008318 

70910345 

74061140 

74062193 
70925995 
74061141 
74061142 
74061135 
74061134 
74062187 
74061133 
74061570 
74062050 

74051559 
74049532 
74048639 
74052915 
74061670 
74061178 
74054579 
74048627 
74049533 
74048635 
74061168 
74062288 
74048624 



74059171 
74062261 
74053267 
70906957 
74053266 
74055293 
74062198 
74048630 
74061206 
74059170 
74061744 
74051412 
74051413 
740545 94 
74056486 
74369478 
74056484 
74056799 
74051409 



QTY. DESCRIPTION 

PUMP ASSY. , 545-B (Includes items 1 thru 160) 
PUMP ASSY. , 605-B (Includes items 1 thru 160) 
NUT, hub retaining 
WASHER, hub retaining 
HUB, gear 
RING, retaining 
WASHER, drive shaft spring 
BEARING, ball 
PIN, spring, drive shaft 
RING, bearing shoulder 
SHAFT, drive 
RING, seal retaining 
2 DSEAL, drive shaft 

2 SCREW, head locking 

CLIP, shaft retainer 

LEVER, throttle shaft 

CAM, shut -off 

SHIM, metering valve 

SPRING, metering valve 

VALVE, metering 

ARM ASSY. , metering valve 

GUIDE, idling spring 

SPRING, idling 

RETAINER, spring 

ARM, governor 

SPRING, governor control (Green- Blue^ 

SPRING, governor linkage 

HOOK ASSY. , governor linkage (Includes items 29,30, 

37, 38) 
LINK ASSY. , adjusting 
HOOK, governor linkage 

3 WASHER, plain 
3 LOCKWASHER, cover screw 
3 SCREW, cover 

CONNECTOR ASSY. , return line 
COVER, governor control 
□ GASKET, governor cover 
WASHER, adjusting link 
SCREW, adjusting link 
SCREW, throttle lever spring 
RETAINER, throttle lever spring 
SPRING, throttle lever 
LEVER ASSY. , throttle 
ARM, adjusting spacer 
SCREW, spacer 
SPACER, throttle lever 
SCREW, low idle adjusting 
NUT, low idle adjusting screw 



e 



(Continued) 



12-7 



(Revised January 1981) 



ITEM 


PART NO. 


QT 


48 


74061716 


1 


49 


74058951 


1 


50 


74058950 


1 


51 


74053375 


2 


52 


74369878 


2 


53 


74050910 


2 


54 


74048642 


2 


55 


74048636 




56 


74369429 


2 


57 


74369428 




58 


74061192 


2 


59 


74048603 




60 


74048604 




61 


74059271 




62 


74061589 




63 


74061170 




64 


74054589 




65 


74059066 




66 


74054585 




67 


74059067 




68 


74369595 




69 


74061130 




70 


74051365 




71 


74061131 




72 


74051378 




73 


74048650 




74 


74369878 




75 


74054582 




76 


74054583 




76A 


74052917 


2 


77 


74051409 


2 


78 


74048632 


2 



INJECTION PUMP PARTS (Continued) 

Y. DESCRIPTION 

SHAFT ASSY. , throttle 

NUT, high idle adjusting screw 

SCREW, high idle adjusting 

□ WASHER, throttle shaft seal 
D SEAL, throttle shaft 

□ SEAL, pivot shaft 
NUT, pivot shaft 

SHAFT, governor arm pivot 
SCREW, name plate 
PLATE, name 
SCREW, timing line cover 
COVER, timing line 

□ GASKET, timing line cover 
PLUG, piston (spring) 
HOUSING ASSY. , pump 

□ SEAL, advance piston hole plug 

□ SEAL, advance piston hole plug 
PIN, advance 

□ SEAL, advance screw hole plug 
PLUG, advance screw hole 

□ SEAL, head locating screw 
SCREW, head locating 

□ SEAL, head locating screw 
PLUG, head locating screw 
STUD, guide 

□ WASHER, guide stud 

□ SEAL, torque screw 
SCREW, torque 
NUT, torque screw 

CAP, cover adjusting screw 

NUT, shut-off arm adjusting screw 

SCREW, shut- off arm adjustment 



( 



c 



82 


74048647 1 


83 


70906957 1 


84 


74061602 1 


85 


74061593 1 


88 


74054583 1 


89 


74369878 1 


90 


74061179 1 


91 


74061127 1 


92 


74061169 2 


93 


74061873 1 


94 


74054589 1 


95 


74062204 1 


96 


74059395 1 


96A 


74059397 1 


97 


74059667 l 


99 


74061128 l 



SCREW, adjusting shut-off return 
WASHER, adjusting shut -off return 
ARM ASSY. , adjusting shut- off 
SHAFT ASSY. , shut-off 
NUT, advance adjusting screw 
D SEAL, advance adjusting screw 
PLUG, piston hole (power) 
VALVE, reed 
SCREW, reed valve 
SEAL, advance piston hole 
SEAL, advance piston hole 
SCREW, advance adjusting 
GUIDE, advance adjusting screw 
RING, spring retaining 
SPRING, outer advance (Yellow- Yellow) 
RING, advance piston 

(Continued) 



12-8 



(Revised December 1979) 



( 



( 



e 



rEM 


PART NO. 


QT 


100 


74059064 


1 


101 


74061677 


1 


102 


74061852 


1 


103 


74061148 


1 


104 


74061149 


6 


105 


74061150 


1 


106 


74055970 


1 


107 


74055890 


2 


108 


74055969 


1 


109 


74369436 


4 


110 


74061157 


4 




74061590 


4 


112 


74061156 


6 


113 


74061155 


3 


114 


74061154 


6 


116 


74062211 


1 


117 


74061188 


1 


118 


74061161 


1 


119 


74061160 


1 


120 


74062 051 


1 


121 


74369444 


1 


122 


74061152 


1 


123 


74061661 


1 


124 


74061663 


2 


125 


74061195 


6 


126 


74061187 


1 


127 


74061159 


1 


128 


74061158 


1 


129 


74061172 


1 


130 


74059733 


4 


131 


74055958 


2 


132 


74061665 


1 


133 


74061162 


1 


134 


74061163 


1 


135 


74061174 


1 


136 


74061164 


1 


137 


74061165 


1 


138 


74061175 


1 


139 


74055960 


1 


140 


74061666 


1 


141 


74061662 


1 


142 


74061664 


1 


143 


74061660 


1 


144 


74053829 


2 


145 


74060067 


3 


146 


74060058 


1 


147 


70912739 


1 


148 


74051383 


2 


149 


74061205 


1 


150 


74049437 


2 



INJECTION PUMP PARTS (Continued) 
QTY. DESCRIPTION 

D SEAL, piston ring 

PISTON, advance 

SLEEVE, governor thrust 

WASHER, governor thrust sleeve 

WEIGHT, governor 

RETAINER ASSY. , governor 

SCREW, leaf spring 

SPRING, leaf 

SCREW, leaf spring 

ROLLER, cam 

SHOE, cam roller (-.508mm)(-. 020") 1 Use as 

SHOE, cam roller (-. 381mm)(-. 015") J required 
D CUSHION 

RETAINER, cushion 
DRING, retaining "E" clip 

VALVE, delivery 

SPRING, delivery valve 

STOP, delivery valve 

SCREW, delivery valve 

RING, cam 
DSEAL, hydraulic head 

HEAD ASSY. (Includes rotor, plungers, 3 screws, 
1 vent wire and item 125) 
DSEAL, transfer pump 

RETAINER, rotor 

CONNECTOR, fuel line 

SCREW, locking plate 

PLATE, locking 

WASHER, locking plate 

LINER, transfer pump 

BLADE, transfer pump 

SPRING, transfer pump blade 

RING, inner locating 

ROLL PIN 
DSEAL, regulating piston 

REGULATOR ASSY. , transfer pump 
DSEAL, inlet filter screen 

PISTON, regulating 

SPRING, regulating 

PLUG ASSY. , end plate adjustment 

RING, screen retainer 

SCREEN, inlet filter 

PLATE, transfer pump pressure 

CAP, transfer pump end 

NUT, lock terminal contact 

WASHER, terminal contact 

WIRE ASSY. , terminal ground 

LOCKWASHER, terminal contact 

WASHER, terminal insulating 

LOCKWASHER, cover screw 

NUT, terminal contact 

(C ontinued ) 



SERVICE MANUAL 
FORM 73112988 



12r9 



(Revised January 1979) 



INJECTION PUMP PARTS (Continued) 
ITEM PART NO. QTY. DESCRIPTION 



151 


74062104 1 


152 


74369502 2 


152A 


74062190 1 


153 


74060214 1 


154 


74369496 1 


155 


74062191 1 


156 


74060210 1 


157 


74369878 1 


158 


74060212 1 


159 


74060211 1 


160 


74060213 1 


161 


74061643 1 



COIL ASSY. , shut-off (12V E. T.R.)(Includes solenoid 
which is not serviced separately and items 144, 145, 
148, 150 and 152 thru 155) 

TUBE 

PLUNGER, solenoid (Not illustrated)- 

SLEEVE, coil arm spring 

SPRING 

ARM ASSY. , solenoid 

RING, over-ride retaining 
DSEAL, over-ride rod 

WASHER, over -ride guide 

GUIDE ASSY. , over -ride 

ROD, over -ride 

GASKET KIT, pump (Includes items 11,36,51,52,53,60, 
63, 64, 66,68, 70, 73, 74, 89, 100, 112, 114, 121, 123, 134, 
136 and 157)(Sufficient quantity for complete overhaul) 

□ Components of item 160 



( 



c 



e 



SERVICE MANUAL 
FORM 73112988 



12-10 



(Revised June 1979) 



MEMO 



( 



C 



e 



SERVICE MANUAL 
FORM 73112988 



(Added January 1979) 



12-11 




SERVICE MANUAL 
FORM 73112988 



T-80630 

INJECTION PUMP PARTS 

12 12 (Added January 1979) 



( 



INJECTION PUMP PARTS 
USAGE: 645-B Wheel Loader (Model 3500 MKII Engine) 
ITEM PART NO. QTY. DESCRIPTION 



c 



c 



- 


74035827 




1 


70910345 




2 


74061132 




3 


74061140 




4 


70925995 




5 


74061141 




6 


74061142 




7 


74061135 




8 


74061134 




9 


74061574 




10 


74061133 




11 


74061570 


2 


13 


74062050 


2 


15 


74051559 




16 


74049532 




17 


74048639 




18 


74052915 




19 


74061670 




20 


74061178 




21 


74054579 




22 


74048627 




23 


74049533 




24 


74048635 




26 


74061168 




27 


74061836 




28 


74048624 




29 


74059171 




30 


74062261 




31 


74053267 


3 


32 


70906957 


3 


33 


74053266 


3 


34 


74055293 




35 


74062198 




36 


74048630 




37 


74061206 




38 


74059170 




39 


74055625 




40 


74051412 




41 


74051413 




42 


74054594 




46 


74056799 




47 


74051409 




48 


74061599 




49 


74061186 




50 


74056799 




51 


74053375 


2 


52 


74369878 


2 


53 


74050910 


2 



PUMP ASSY., injection (Includes items 1 thru 160) 
NUT, hub retaining 
WASHER, hub retaining 
HUB, gear 
RING, retaining 
WASHER, drive shaft spring 
BEARING, ball 
PIN, spring, drive shaft 
RING, bearing shoulder 
SHAFT, drive 
RING, seal retaining 
□ SEAL, drive shaft 
SCREW, head locking 
CLIP, shaft retainer 
LEVER, throttle shaft 
CAM, shut- off 
SHIM, metering valve 
SPRING, metering valve 
VALVE, metering 
ARM ASSY. , metering valve 
GUIDE, idling spring 
SPRING, idling 
RETAINER, spring 
ARM, governor 

SPRING, governor control (Blue- Blue) 
SPRING, governor linkage 
HOOK ASSY., governor linkage (Includes items 29, 

30, 37, 38) 
LINK ASSY., adjusting 
HOOK, governor linkage 
WASHER, plain 
LOCKWASHER, cover screw 
SCREW, cover 

CONNECTOR ASSY., return line 
COVER, governor control 

□ GASKET, governor cover 
WASHER, adjusting link 
SCREW, adjusting link 
SCREW, throttle lever spring 
RETAINER, throttle lever spring 
SPRING, throttle lever 
LEVER ASSY. , throttle 
SCREW, low idle adjusting 
NUT, low idle adjusting screw 
SHAFT ASSY. , throttle 

NUT, high idle adjusting screw 
SCREW, high idle adjusting 

□ WASHER, throttle shaft seal 

□ SEAL, throttle shaft 

□ SEAL, pivot shaft 



(Continued) 



12-13 



(Revised December 197 9) 



[TEM 


PART NO. 


QTY. 




54 


74048642 


2 




55 


74048636 


1 




56 


74369429 


2 




57 


74369428 


1 




58 


74061192 


2 




59 


74048603 


1 




60 


74048604 


1 


□ 


61 


74059061 


1 




62 


74061599 


1 




63 


74061170 


1 


□ 


64 


74054589 


1 


□ 


65 


74059066 


1 




66 


74054585 


1 


□ 


67 


74059067 


1 




68 


74369595 


1 


□ 


69 


74061130 


1 




70 


74051365 


1 


D 


71 


74061131 


1 




72 


74051378 


1 




73 


74048650 


1 


□ 


74 


74369878 


1 


D 


75 


74054582 


1 




76 


74054583 


1 




76A 


74052917 


2 




77 


74051409 


2 




78 


74048632 


2 




80 


70912739 






81 


74369478 






82 


74048647 






83 


70906957 






84 


74062371 






85 


74060735 






88 


74054583 






89 


74369878 




□ 


90 


74061179 






91 


74062909 






92 


74061169 


2 




93 


74061873 






94 


74054589 






95 


74062204 






96 


74059395 






96A 


7405 9397 






97 


7405 9662 






99 


74061128 






100 


74059064 




□ 


101 


74061667 






102 


74061852 






103 


74061148 






104 


74061149 


6 




105 


74061150 






106 


74055970 






107 


74055890 


2 





INJECTION PUMP PARTS (Continued) 

DESCRIPTION 

NUT, pivot shaft 

SHAFT, governor arm pivot 

SCREW, name plate 

PLATE, name 

SCREW, timing line cover 

COVER, timing line 

GASKET, timing line cover 

PLUG, piston (spring) 

HOUSING ASSY. , pump 

SEAL, advance piston hole plug 

SEAL, advance piston hole plug 

PIN, advance 

SEAL, advance screw hole plug 

PLUG, advance screw hole 

SEAL, head locating screw 

SCREW, head locating 

SEAL, head locating screw 

PLUG, head locating screw 

STUD, guide 

WASHER, guide stud 

SEAL, torque screw 

SCREW, torque 

NUT, torque screw 

GAP, cover adjusting screw 

NUT, shut-off arm adjusting screw 

SCREW, shut- off arm adjustment 

WASHER, adjusting shut-off position screw 

SCREW, adjusting shut- off position 

SCREW, adjusting shut-off return 

WASHER, adjusting shut- off return 

ARM ASSY. , adjusting shut- off 

SHAFT ASSY., shut-off 

NUT, advance adjusting screw 

SEAL, advance adjusting screw 

PLUG, piston hole (power) 

VALVE, reed 

SCREW, reed valve 

SEAL, advance piston hole 

SEAL, advance piston hole 

SCREW, advance adjusting 

GUIDE, advance adjusting screw 

RING, spring retaining 

SPRING, outer advance (Black-Green) 

RING, advance piston 

SEAL, piston ring 

PISTON, advance 

SLEEVE, governor thrust 

WASHER, governor sleeve 

WEIGHT, governor 

RETAINER ASSY., governor 

SCREW, leaf spring 

SPRING, leaf 

(Continued) 



( 



c 



c 



12-14 



(Revised January 1981) 



( 



e 



DEM 


PART NO. < 


31"} 


108 


74055969 


1 


109 


74369436 


4 


110 


74061590 


4 




74061509 


4 




74061157 


4 


112 


74061156 


6 


113 


74061155 


3 


114 


74061154 


6 


116 


74062211 


1 


117 


74061188 


1 


118 


74061161 


1 


119 


74061160 


1 


120 


74062 051 


1 


121 


74369444 


1 


122 


74062195 


1 


123 


74061661 


1 


124 


74061663 


2 


125 


74061195 


6 


126 


74061187 


1 


127 


74061159 


1 


128 


74061158 


1 


129 


74061172 


1 


130 


74059733 


4 


131 


74055958 


2 


132 


74061665 


1 


133 


74061162 


1 


134 


74061163 


1 


135 


74061174 


1 


136 


74061164 


1 


137 


74061165 


1 


138 


74061175 


1 


139 


74055960 


1 


140 


74061666 


1 


141 


74061662 


1 


142 


74061664 


1 


143 


74061660 


1 


144 


74053829 


2 


145 


74060067 


3 


146 


74060058 


1 


147 


70912739 


1 


148 


74051383 


2 


149 


74061205 


1 


150 


74049437 


2 


151 


74062197 


1 


151A 


74062190 


1 


152 


74369502 


2 


153 


74060214 


1 


154 


74369496 


1 


155 


74062191 


1 


156 


74060210 


1 


157 


74369878 


1 


SERVICE MANUAL 




FORM 73112988 





INJECTION PUMP PARTS (Continued) 

DESCRIPTION 

SCREW, leaf spring 

ROLLER, cam 

SHOE, cam roller (-. 381mm)(-. 015") ^ Use 

SHOE, cam roller (-. 254mm)(-. 010") > as 

SHOE, cam roller (-. 508mm)(-. 020") J required 

CUSHION 

RETAINER, cushion 
DRING, retaining "E" clip 

VALVE, delivery 

SPRING, delivery valve 

STOP, delivery valve 

SCREW, delivery valve 

RING, cam 
nSEAL, hydraulic head 

HEAD ASSY o (Includes rotor, plungers, 3 screws, 
1 vent wire and item 125) 
DSEAL, transfer pump 

RETAINER, rotor 

CONNECTOR, fuel line 

SCREW, locking plate 

PLATE, locking 

WASHER, locking plate 

LINER, transfer pump 

BLADE, transfer pump 

SPRING, transfer pump blade 

RING, inner locating 

ROLL PIN 
DSEAL, regulating piston 

REGULATOR ASSY. , transfer pump 
DSEAL, inlet filter screen 

PISTON, regulating 

SPRING, regulating 

PLUG ASSY. , end plate adjustment 

RING, screen retainer 

SCREEN, inlet filter 

PLATE, transfer pump pressure 

CAP, transfer pump end 

NUT, lock terminal contact 

WASHER, terminal contact 

WIRE ASSY. , terminal ground 

LOCKWASHER, terminal contact 

WASHER, terminal insulating 

LOCKWASHER, cover screw 

NUT, terminal contact 

COIL ASSY., shut-off (24V. E. T. R. )(Includes 
solenoid which is not serviced spearately and 
items 144, 145, 148, 150, 151A and 152 thru 155) 

PLUNGER, solenoid (Not illustrated) 

TUBE 

SLEEVE, coil arm spring 

SPRING 

ARM ASSY., solenoid 



RING, over-ride retaining 
DSEAL, over-ride rod 
(Continued) 
12-15 



(Added January 197 9) 



ITEM 



INJECTION PUMP PARTS (Continued) 
PART NO. QTY. DESCRIPTION 



158 


74060212 


1 


159 


74060211 


1 


160 


74060213 


1 


161 


74061643 


1 



WASHER, over- ride guide 

GUIDE ASSY., over-ride 

ROD, over-ride 

GASKET KIT, pump (Includes items 11,36,51,52,53, 
60,63,64,66,68,70,73,74,89,100,112,114,121,123, 
134, 136 and 157)(Sufficient quantity for complete 
overhaul) 

n Components of item 161 



( 



c 



SERVICE MANUAL 
FORM 73112988 



12-16 



(Revised May 1979) 



MEMO 



( 



c 



c 



SERVICE MANUAL 
FORM 73112988 



12-17 



(Added January 197 9)^ 




( 



SERVICE MANUAL 
FORM 73112988 



INJECTION PUMP PARTS 
12-18 



(Added January 1979) 



c 



INJECTION PUMP PARTS 
USAGE: 645-B Wheel Loader (Model 3500 MK II Engine) 
ITEM PART NO. QTY. DESCRIPTION 



c 



- 


74036268 




1 


70910345 




2 


74061132 




3 


74061140 




4 


70925995 




5 


74061141 




6 


74061142 




7 


74061135 




8 


74061134 




9 


74061574 




10 


74061133 




11 


74061570 


2 


13 


74062050 


2 


15 


74051559 




16 


74049532 




17 


74048639 




18 


74052915 




19 


74061670 




20 


74061178 




21 


74054579 




22 


74048627 




23 


74049533 




24 


74048635 




26 


74061168 




27 


74061836 




28 


74048624 




29 


74059171 




30 


74062261 




31 


74053267 


3 


32 


70906957 


3 


33 


74053266 


3 


34 


74055293 




35 


74062198 




36 


74048630 




37 


74061206 




38 


74059170 




39 


74055625 




40 


74051412 




41 


74051413 




42 


74054594 




46 


74056799 




47 


74051409 




48 


74061599 




49 


74061186 




50 


74056799 




51 


74053375 


2 


52 


74369878 


2 


53 


74050910 


2 


54 


74048642 


2 



PUMP ASSY., injection (Includes items 1 thru 168) 

NUT, hub retaining 

WASHER, hub retaining 

HUB, gear 

RING, retaining 

WASHER, drive shaft spring 

BEARING, ball 

PIN, spring, drive shaft 

RING, bearing shoulder 

SHAFT, drive 

RING, seal retaining 

□ SEAL, drive shaft 
SCREW, head locking 
CLIP, shaft retainer 
LEVER, throttle shaft 
CAM, shut- off 
SHIM, metering valve 
SPRING, metering valve 
VALVE, metering 

ARM ASSY. , metering valve 

GUIDE, idling spring 

SPRING, idling 

RETAINER, spring 

ARM, governor 

SPRING, governor control (Blue -Blue) 

SPRING, governor linkage 

HOOK ASSY., governor linkage (Includes items 29,30, 
37, 38) 

LINK ASSY. , adjusting 

HOOK, governor linkage 

WASHER, plain 

LOCKWASHER, cover screw 

SCREW, cover 

CONNECTOR ASSY. , return line 

COVER, governor control 
D GASKET, governor cover 

WASHER, adjusting link 

SCREW, adjusting link 

SCREW, throttle lever spring 

RETAINER, throttle lever spring 

SPRING, throttle lever 

LEVER ASSY. , throttle 

SCREW, low idle adjusting 

NUT, low idle adjusting screw 

SHAFT ASSY. , throttle 

NUT, high idle adjusting screw 

SCREW, high idle adjusting 
□WASHER, throttle shaft seal 

□ SEAL, throttle shaft 

□ SEAL, pivot shaft 
NUT, pivot shaft 

(Continued) 



12-19 



(Revised December 1979) 



TEM 


PART NO. QT 


55 


74048636 1 


56 


74369429 2 


57 


74369428 1 


58 


74061192 2 


59 


74048603 1 


60 


74048604 1 


61 


74059061 1 


62 


74061589 1 


63 


74061170 1 


64 


74054589 1 


65 


74059066 1 


66 


74054585 1 


67 


74059067 1 


68 


74369595 1 


69 


74061130 1 


70 


74051365 1 


71 


74061131 1 


72 


74051378 1 


73 


74048650 1 


74 


74369878 1 


75 


74054582 1 


76 


74054583 1 


76A 


74052917 2 


77 


74051409 2 


78 


74048632 2 


80 


70912739 1 


81 


74369478 1 


82 


74048647 1 


83 


70906957 1 


84 


74061602 1 


85 


74061593 1 


88 


74054583 1 


89 


74369878 1 


90 


74061179 1 


91 


74061127 1 


92 


74061169 2 


93 


74061873 1 


94 


74054589 1 


95 


74062204 1 


96 


74059395 1 


96A 


74059397 1 


97 


74059662 1 


99 


74061128 1 


100 


74059064 1 


101 


74061667 1 


102 


74061852 1 


103 


74061148 1 


104 


74061149 6 


105 


74061150 1 


106 


74055970 1 


107 


74055890 2 


108 


74055969 1 



INJECTION PUMP PARTS (Continued) 
DESCRIPTION 

SHAFT, governor arm pivot 

SCREW, name plate 

PLATE, name 

SCREW, timing line cover 

COVER, timing line 
□ GASKET, timing line cover 

PLUG, piston (spring) 

HOUSING ASSY. , pump 
DSEAL, advance piston hole plug 
DSEAL, advance piston hole plug 

PIN, advance 
DSEAL, advance screw hole plug 

PLUG, advance screw hole 
DSEAL, head locating screw 

SCREW, head locating 
DSEAL, head locating screw 

PLUG, head locating screw 

STUD, guide 
D WASHER, guide stud 
DSEAL, torque screw 

SCREW, torque 

NUT, torque screw 

CAP, cover adjusting screw 

NUT, shut-off arm adjusting screw 

SCREW, shut- off arm adjustment 

WASHER, adjusting shut-off position screw 

SCREW, adjusting shut-off position 

SCREW, adjusting shut-off return 

WASHER, adjusting shut- off return 

ARM ASSY., adjusting shut- off 

SHAFT ASSY. , shut- off 

NUT, advance adjusting screw 
DSEAL, advance adjusting screw 

PLUG, piston hole (power) 

VALVE, reed 

SCREW, reed valve 

SEAL, advance piston hole 

SEAL, advance piston hole 

SCREW, advance adjusting 

GUIDE, advance adjusting screw 

RING, spring retaining 

SPRING, outer advance (Black-Green) 

RING, advance piston 
D SEAL, piston ring 

PISTON, advance 

SLEEVE, governor thrust 

WASHER, governor thrust sleeve 

WEIGHT, governor 

RETAINER ASSY., governor 

SCREW, leaf spring 

SPRING, leaf 

SCREW, leaf spring 



r 



c 



(Continued) 
12-20 



e 



(Revised December 1979) 



ITEM 



INJECTION PUMP PARTS (Continued) 
PART NO. QTY. DESCRIPTION 



( 



c 



c 



109 


74369436 


4 


110 


74061590 


4 




74061509 


4 




74061157 


4 


112 


74061156 


6 


113 


74061155 


3 


114 


74061154 


6 


116 


74062211 


1 


117 


74061188 


1 


118 


74061161 


1 


119 


74061160 


1 


120 


74062051 


1 


121 


74369444 


1 


122 


74061152 


1 


123 


74061661 


1 


124 


74061663 


2 


125 


74061195 


6 


126 


74061187 


1 


127 


74061159 


1 


128 


74061158 


1 


129 


74061172 


1 


130 


74059733 


4 


131 


74055958 


2 


132 


74061665 


1 


133 


74061162 


1 


134 


74061163 


1 


135 


74061174 


1 


136 


74061164 


1 


137 


74061165 


1 


138 


74061175 


1 


139 


74055960 


1 


140 


74061666 


1 


141 


74061662 


1 


142 


74061664 


1 


143 


74061660 


1 


144 


74053829 


2 


145 


74060067 


3 


146 


74060058 


1 


147 


70912739 


1 


148 


74051383 


2 


149 


74061205 


1 


150 


74049437 


2 


151 


74062197 


1 


151A 


74062190 


1 


152 


74369502 


2 


153 


74060214 


1 


154 


74369496 


1 


155 


74062191 


1 


156 


74060210 


1 


157 


74369878 


1 


158 


74060212 


1 


SERVICE MANUAL 




FORM 73112988 






ROLLER, cam 

SHOE, cam roller (-. 381mm)(-. 015") 
SHOE, cam roller (-. 254mm)(-. 010") 
SHOE, cam roller (-. 508mm)(-. 020") 

□ CUSHION 

RETAINER, cushion 
DRING, retaining "E" clip 

VALVE, delivery 

SPRING, delivery valve 

STOP, delivery valve 

SCREW, delivery valve 

RING, cam 
DSEAL, hydraulic head 

HEAD ASSY. (Includes rotor, plungers, 3 screws, 
1 vent wire and item 125) 
DSEAL, transfer pump 

RETAINER, rotor 

CONNECTOR, fuel line 

SCREW, locking plate 

PLATE, locking 

WASHER, locking plate 

LINER, transfer pump 

BLADE, transfer pump 

SPRING, transfer pump blade 

RING, inner locating 

ROLL PIN 
DSEAL, regulating piston 

REGULATOR ASSY. , transfer pump 
DSEAL, inlet filter screen 

PISTON, regulating 

SPRING, regulating 

PLUG ASSY., end plate adjustment 

RING, screen retainer 

SCREEN, inlet filter 

PLATE, transfer pump pressure 

CAP, transfer pump end 

NUT, lock terminal contact 

WASHER, terminal contact 

WIRE ASSY. , terminal ground 

LOCKWASHER, terminal contact 

WASHER, terminal insulating 

LOCKWASHER, cover screw 

NUT, terminal contact 

COIL ASSY., shut-off (24V. E. T. R. )(Includes 
solenoid which is not serviced separately and 
items 144, 145, 148, 150, 151A and 152 thru 155) 

PLUNGER, solenoid (Not illustrated) 

TUBE 

SLEEVE, coil arm spring 

SPRING 

ARM ASSY. , solenoid 

RING, over-ride retaining 
DSEAL, over-ride rod 

WASHER, over-ride guide 

(Continued) 
12-21 



(Added January 1979) 



ITEM PART NO, 



159 
160 
161 



162 
163 
164 
165 
166 
167 
168 
169 



74060211 
74060213 
74061591 



74061592 
70906957 
74061780 
74061594 
74061595 
74061596 
74061597 
74061643 



INJECTION PUMP PARTS (Continued) 
QTY. DESCRIPTION 

1 GUIDE ASSY. , over-ride 

1 ROD, over- ride 

1 ANEROID ASSY. (Serviced only as a unit. (Includes 

Cap Assy., Piston Assy,, Shims, Spring and 
Body which are not serviced separately) 

4 SCREW, bracket mounting 

4 WASHER, bracket mounting 

1 BRACKET, aneroid mounting 

1 NUT, body assembly retaining 

1 BOOT, aneroid 

1 ROD, operating 

2 RING, retaining 

1 GASKET KIT, pump (Includes items 11,36,51,52,53, 

60,63,64,66,68,70,73,74,89, 100,112,114,121,123, 
134, 136 and 157)(Sufficient quantity for complete 
overhaul) 

□ Components of item 169 



( 



c 



c 



SERVICE MANUAL 
FORM 73112988 



12-22 



(Added January 1979) 



MEMO 



( 



c 



e 



SERVICE MANUAL 
FORM 73112988 



12-23 



(Added January 1979) 



-161 




T-80630 



SERVICE MANUAL 
FORM 73112988 



INJECTION PUMP PARTS 
12-24 



(Added January 197 9) 



( 



c 



c 



INJECTION PUMP PARTS 
USAGE: 745-C Wheel Loader (Model 11000 MK II Engine) 
ITEM PART NO. QTY. DESCRIPTION 



- 


74321924 




- 


74322021 




1 


70910345 




2 


74061132 




3 


74062193 




4 


70925995 




5 


74061141 




6 


74061142 




7 


74061135 




8 


74061134 




9 


74062187 




10 






11 


74061570 


2 


13 


74062050 


2 


14 


74062183 




15 


74051559 




16 


74049532 




17 


74048639 




18 


74052915 




19 


74061670 




20 


74061709 




21 


74062848 




22 


74048627 




23 


74049533 




24 


74048635 




26 


74061168 




27 


74061836 




28 


74048624 




29 


74059171 




30 


74061704 




31 


74053267 


3 


32 


70906957 


3 


33 


74053266 


3 


34 


74055293 




35 


74062198 




36 


74048630 




37 


74061206 




38 


74059170 




39 


74061744 




40 


74051412 




41 


74051413 




42 


74054594 




43 


74056486 




44 


74369478 




45 


74056484 




46 


74051799 




47 


74051409 




48 


74061716 




49 


74051409 





Includes items 
1 thru 168 



PUMP ASSY., injection 

PUMP ASSY. , injection 

NUT, hub retaining 

WASHER, hub retaining 

HUB, gear 

RING, retaining 

WASHER, drive shaft spring 

BEARING, ball 

PIN, spring, drive shaft 

RING, bearing shoulder 

SHAFT, drive 

RING, seal retaining (Not required) 

□ SEAL, drive shaft 
SCREW, head locking 
SEAL, pump flange 
CLIP, shaft retainer 
LEVER, throttle shaft 
CAM, shut- off 
SHIM, metering valve 
SPRING, metering valve 
VALVE, metering 

ARM ASSY., metering valve 

GUIDE, idling spring 

SPRING, idling 

RETAINER, spring 

ARM, governor 

SPRING, governor control (Blue -Blue) 

SPRING, governor linkage 

HOOK ASSY., governor linkage (Includes items 29, 

30, 37, 38) 
LINK ASSY., adjusting 
HOOK, governor linkage 
WASHER, plain 
LOCKWASHER, cover screw 
SCREW, cover 

CONNECTOR ASSY. , return line 
COVER, governor control 

□ GASKET, governor cover 
WASHER, adjusting link 
SCREW, adjusting link 
SCREW, throttle lever spring 
RETAINER, throttle lever spring 
SPRING, throttle lever 
LEVER ASSY., throttle 

ARM, adjusting spacer 
SCREW, spacer 
SPACER, throttle lever 
SCREW, low idle adjusting 
NUT, low idle adjusting screw 
SHAFT ASSY. , throttle 
NUT, high idle adjusting screw 



(Continued) 
12-25 



(Revised January 1981) 



rEM 


PART NO. 


QT" 


50 


74056799 


1 


51 


74053375 


2 


52 


74369878 


2 


53 


74050910 


2 


54 


74048642 


2 


55 


74048636 




56 


74369429 


2 


57 


74369428 




58 


74061192 


2 


59 


74048603 




60 


74048604 




61 


74059271 




62 


74062184 




63 


74061170 




64 


74054589 




65 


74059066 




66 


74054585 




67 


74059067 




68 


74369595 




69 


74061130 




70 


74051365 




71 


74061131 




72 


74051378 




73 


74048650 




74 


74369878 




75 


74054582 




76 


74054583 




76A 


74052917 


2 


77 


74051409 


2 


78 


74048632 


2 


80 


70912739 




81 


74369478 




82 


74048647 




83 


70906957 




84 


74061602 




85 


74061593 




88 


74054583 




89 


74369878 




90 


74062194 




91 


74061127 




92 


74061169 


2 


93 


74061873 




94 


74054589 




95 


74054593 




96 


74054591 




97 


74062182 
74062266 




99 


74061128 




100 


74059064 




101 


74062192 




102 


74061852 




103 


74061148 




104 


74061149 


6 



INJECTION PUMP PARTS (Continued) 
DESCRIPTION 

SCREW, high idle adjusting 
□WASHER, throttle shaft seal 
□SEAL, throttle shaft 
□SEAL, pivot shaft 

NUT, pivot shaft 

SHAFT, governor arm pivot 

SCREW, name plate 

PLATE, name 

SCREW, timing line cover 

COVER, timing line 
□GASKET, timing line cover 

PLUG, piston (spring) 

HOUSING ASSY. , pump 
□SEAL, advance piston hole plug 
□SEAL, advance piston hole plug 

PIN, advance 
□SEAL, advance screw hole plug 

PLUG, advance screw hole 

□ SEAL, head locating screw 
SCREW, head locating 

□SEAL, head locating screw 
PLUG, head locating screw 
STUD, guide 

□ WASHER, guide stud 
□SEAL, torque screw 

SCREW, torque 

NUT, torque screw 

CAP, cover adjusting screw 

NUT, shut-off arm adjusting screw 

SCREW, shut- off arm adjustment 

WASHER, adjusting shut- off position screw 

SCREW, adjusting shut-off position 

SCREW, adjusting shut-off return 

WASHER, adjusting shut- off return 

ARM ASSY., adjusting shut-off 

SHAFT ASSY., shut-off 

NUT, advance adjusting screw 

□ SEAL, advance adjusting screw 
PLUG, piston hole (power) 
VALVE, reed 
SCREW, reed valve 
SEAL, advance piston hole 
SEAL, advance piston hole 
SCREW, advance adjusting 
GUIDE, advance adjusting screw 

SPRING, outer advance (Br own)(For 74321924 Pump Assy.) 
SPRING,outer advance (Blue) (For 74322021 Pump Assy.) 
RING, advance piston 

□SEAL, piston ring 
PISTON, advance 
SLEEVE, governor thrust 
WASHER, governor thrust sleeve 
WEIGHT, governor 



c 



c 



(Continued) 
12-26 



(Revised December 1979) 



( 



c 



:em 


PART NO. 


QT^ 


105 


74061150 


1 


106 


74055970 


1 


107 


74055890 


2 


108 


74055969 


1 


109 


74369436 


4 


110 


74061509 


4 




74061156 


4 




74061590 


4 


112 


74061156 


6 


113 


74061155 


3 


114 


74061154 


6 


116 


74062189 


1 


117 


74061188 


1 


118 


74061161 


1 


119 


74061160 


1 


119A 


74059390 


2 


119B 


74059392 


2 


119C 


74059391 


2 


120 


74062051 


1 


121 


74369444 


1 


122 


74062195 


1 




74061702 


1 


123 


74061661 


1 


124 


74061663 


2 


125 • 


74061195 


6 


126 


74061187 


1 


127 


74061159 


1 


129 


74061172 


1 


130 


74059733 


4 


131 


74055958 


2 


132 


74061665 


1 


133 


74061162 


1 


134 


74061163 


1 


135 


74061174 


1 


136 


74061164 


1 


137 


74061165 


1 


138 


74061175 


1 


139 


74055960 


1 


140 


74061666 


1 


141 


74061662 


1 


142 


74061664 


1 


143 


74061660 


1 


144 


74053829 


2 


145 


74060067 


3 


146 


74060058 


1 


147 


70912739 


1 


148 


74051383 


2 


149 


74061205 


1 


150 


74049437 


2 


151 


74062197 


1 



Use 

as 

required 



Not used 
on pump 
No. 
74322021 



151A 74062190 

SERVICE MANUAL 
FORM 73112988 



INJECTION PUMP PARTS (Continued) 
DESCRIPTION 

RETAINER ASSY. , governor 
SCREW, leaf spring 
SPRING, leaf 
SCREW, leaf spring 
ROLLER, cam 

SHOE, cam roller (-. 254mm)(-. 010") 
SHOE, cam roller (-. 127mm)(-. 005") 
SHOE, cam roller (-. 381mm)(-. 015") 
DCUSHION 

RETAINER, cushion 
DRING, retaining "E" clip 
VALVE, delivery 

SPRING, delivery valve 

STOP, delivery valve 

SCREW, delivery valve 
* PIS TON, accumulator 
*SPRING, accumulator 
*SCREW, accumulator, piston return 
*(Not illustrated) 

RING, cam 
DSEAL, hydraulic head 

HEAD ASSY. (For 74321924 ~\ Each includes rotor, 
Pump Assy. ) [plungers, 3 screws 1 

HEAD ASSY. (For 74322021 [vent wire and item 
Pump Assy. ) J 125 

DSEAL, transfer pump 

RETAINER, rotor 

CONNECTOR, fuel line 

SCREW, locking plate 

PLATE, locking 

LINER, transfer pump 

BLADE, transfer pump 

SPRING, transfer pump blade 

RING, inner locating 

ROLL PIN 
DSEAL, regulating piston 

REGULATOR ASSY. , transfer pump 
DSEAL, inlet filter screen 

PISTON, regulating 

SPRING, regulating 

PLUG ASSY. , end plate adjustment 

RING, screen retainer 

SCREEN, inlet filter 

PLATE, transfer pump pressure 

CAP, transfer pump end 

NUT, lock terminal contact 

WASHER, terminal contact 

WIRE ASSY. , terminal ground 

LOCKWASHER, terminal contact 

WASHER, terminal insulating 

LOCKWASHER, cover screw 

NUT, terminal contact 

COIL ASSY., shut- off (24V. E. T. R. )(Includes 
solenoid which is not serviced separately and 
items 144, 145, 148, 150, 151A and 152 thru 155) 

PLUNGER, solenoid (Not illustrated) 

(Continued) 
12-27 



(Added January 1979) 



ITEM 


PART NO. 


QTY 


152 


74369502 


2 


153 


74060214 




154 


74369496 




155 


74062191 




156 


74060210 




157 


74369878 




158 


74060212 




159 


74060211 




160 


74060213 




161 


74061591 




162 


74061592 


4 


163 


70906957 


4 


164 


74061593 


1 


165 


74061594 


1 


166 


74061595 


1 


167 


74061596 


1 


168 


74061597 


2 


169 


74061643 


1 



INJECTION PUMP PARTS (Continued) 

DESCRIPTION 

TUBE 

SLEEVE, coil arm spring 

SPRING 

ARM ASSY. , solenoid 

RING, over-ride retaining 
□ SEAL, over-ride rod 

WASHER, over-ride guide 

GUIDE ASSY., over-ride 

ROD, over-ride 

ANEROID ASSY. (Serviced only as a unit. Includes 
Cap Assy., Piston Assy., Shims, Spring and 
Body which are not serviced separately) 

SCREW, bracket mounting 

WASHER, bracket mounting 

BRACKET, aneroid mounting 

NUT, body assembly retaining 

BOOT, aneroid 

ROD, operating 

RING, retaining 

GASKET KIT, pump (Includes items 11,36,51,52,53, 
60,63,64,66,68,70,73, 74,89, 100, 112,114, 121, 123, 
134, 136 and 157)(Sufficient quantity for complete 
overhaul) 

□ Components of item 169 



( 



c 



c 



SERVICE MANUAL 
FORM 73112988 



12-28 



(Added January 197 9) 



MEMO 



C 



C 



c 



SERVICE MANUAL 
FORM 73112988 



12-29 



(Added January 197 9> 




SERVICE MANUAL 
FORM 73112988 



INJECTION PUMP PARTS 
12-30 



T-80630 



(Revised June 1979) 



INJECTION PUMP PARTS 



( 



C 



C 



USAGE: 100-C, 150-C, 200-C Graders (Model 11000 MK II. and 685T) 
ITEM PART NO. QTY. DESCRIPTION 

PUMP ASSY., injection (100-C, 150-C )(Includes 

items 1 thru 143) 
PUMP ASSY., injection (2 00-C ) (Includes items 1 

thru 143) 
NUT, hub retaining 
WASHER, hub retaining 
HUB, gear 
RING, retaining 
WASHER, drive shaft spring 
BEARING, ball 
PIN, spring, drive shaft 
RING, bearing shoulder 
SHAFT, drive 
RING, seal retaining 

□ SEAL, drive shaft 
SCREW, head locking 
SEAL, pump flange 
CLIP, shaft retainer 
LEVER, throttle shaft 
CAM, shut- off 
SHIM, metering valve 
SPRING, metering valve 
VALVE, metering 

ARM ASSY. , metering valve (100-C, 15 0-C) 
ARM ASSY. , metering valve (200-C) 
GUIDE, idling spring 
SPRING, idling 
RETAINER, spring 
ARM, governor 

SPRING, governor control (Black- Black) (2 00-C) 
SPRING, governor control (Black- Br own)'(100-C , 150-C ) 
SPRING, governor linkage ^ 
HOOK ASSY., governor linkage (Includes items 29, 

30, 37, 38) 
LINK ASSY. , adjusting 
HOOK, governor linkage 
WASHER, plain 
LOCKWASHER, cover screw 
SCREW, cover 

CONNECTOR ASSY. , return line 
COVER, governor control 

□ GASKET, governor cover 
WASHER, adjusting link 
SCREW, adjusting link 
SCREW, throttle lever spring 
RETAINER, throttle lever spring 
SPRING, throttle lever 
LEVER ASSY. , throttle 
ARM, adjusting spacer 
SCREW, spacer 
SPACER, throttle lever 
SCREW, low idle adjusting 
NUT, low idle adjusting screw 

(Continued) 

12-31 (Revised January 1981) 



- 


74321756 




- 


74321882 




1 


70910345 




2 


74061132 




3 


74062193 




4 


70925995 




5 


74061141 




6 


74061142 




7 


74061135 




8 


74061134 




9 


74062187 




10 


74061133 




11 


74061570 


2 


13 


74062050 


2 


14 


74062183 




15 


74051559 




16 


74049532 




17 


74048639 




18 


74052915 




19 


74061670 




20 


74061709 




21 


74061703 
74062848 




22 


74048627 




23 


74049533 




24 


74048635 




26 


74061168 




27 


74061835 
74061781 




28 


74048624 




29 


74059171 




30 


74061704 




31 


74053267 


2 


32 


70906957 


2 


33 


74053266 


2 


34 


74055293 




35 


74051002 




36 


74048630 




37 


74061206 




38 


74059170 




39 


74061744 




40 


74051412 




41 


74051413 




42 


74054594 




43 


74056486 




44 


74369478 




45 


74056484 




46 


74048645 




47 


74051409 





tem 


PART NO. 


QT 


48 


74056488 


1 


49 


74051409 


1 


50 


74056799 


1 


51 


74053375 


2 


52 


74369878 


2 


53 


74050910 


2 


54 


74048642 


2 


55 


74048636 




56 


74369429 


2 


57 


74369428 




58 


74061192 


2 


59 


74048603 




60 


74048604 




61 


74059271 




62 


74062184 




63 


74061170 




64 


74054589 




65 


74059066 




66 


74054585 




67 


74059067 




68 


74369595 




69 


74061130 




70 


74051365 




71 


74061131 




72 


74051378 




73 


74048650 




74 


74369878 




75 


74054582 




76 


74054583 




76A 


74052917 


2 


77 


74051409 


2 


78 


74048632 


2 


79 


74056484 




80 


74369478 




81 


74056486 




82 


74054594 




83 


74051413 




84 


74051412 




84A 


74056487 




85 


74056490 




88 


74054583 




89 


74369878 




90 


74062194 




91 


74061716 




92 


74061169 




93 


74061873 




94 


74054589 




95 


74054593 




96 


74054591 




97 


74062182 




99 


74061128 




100 


74059064 





INJECTION PUMP PARTS (Continued) 

DESCRIPTION 

SHAFT ASSY. , throttle 

NUT, high idle adjusting screw 

SCREW, high idle adjusting 

□ WASHER, throttle shaft seal 

□ SEAL, throttle shaft 
□SEAL, pivot shaft 

NUT, pivot shaft 

SHAFT, governor arm pivot 

SCREW, name plate 

PLATE, name 

SCREW, timing line cover 

COVER, timing line 

□ GASKET, timing line cover 
PLUG, piston (spring) 
HOUSING ASSY., pump 

□ SEAL, advance piston hole plug 
□SEAL, advance piston hole plug 

PIN, advance 
□SEAL, advance screw hole plug 

PLUG, advance screw hole 
□SEAL, head locating screw 

SCREW, head locating 
□SEAL, head locating screw 

PLUG, head locating screw 

STUD, guide 
□WASHER, guide stud 

□ SEAL, torque screw 
SCREW, torque 
NUT, torque screw 
CAP, cover adjusting screw 
NUT, shut-off arm adjusting screw 
SCREW, shut-off arm adjusting 
SPACER, shut-off lever 
SCREW, shut- off position screw 
ARM, adjusting spacer 
LEVER ASSY., shut-off 
SPRING, shut- off lever 
RETAINER, throttle lever spring 
SCREW, shut-off lever spring 
SHAFT ASSY., shut-off 
NUT, advance adjusting screw 

□ SEAL, advance adjusting screw 
PLUG, piston hole (power) 
VALVE, reed 
SCREW, reed valve 
SEAL, advance piston hole 
SEAL, advance piston hole 
SCREW, advance adjusting 
GUIDE, advance adjusting screw 
SPRING, outer advance (Brown) 
RING, advance piston 

□ SEAL, piston ring 

(Continued) 



( 



c 



c 



12-32 



(Revised January 1981) 



( 



c 



c 



rEM 


PART NO. 


QT 


101 


74062192 


1 


102 


74061852 


1 


103 


74061148 


1 


104 


74061149 


6 


105 


74061150 


1 


106 


74055970 


1 


107 


74055890 


2 


108 


74055969 


1 


109 


74369436 


4 


110 


74061157 


4 




74061590 


4 




74061512 


4 


112 


74061156 


6 


113 


74061155 


3 


114 


74061154 


6 


116 


74062189 


1 


117 


74061188 


1 


118 


74061161 


1 


119 


74061160 


1 


120 


74062051 


1 


121 


74369444 


1 


122 


74062195 


1 


123 


74061661 


1 


124 


74061663 


2 


125 


74061195 


6 


126 


74061187 


1 


127 


74062282 


1 


129 


74061172 


1 


130 


74059733 


4 


131 


74055958 


2 


132 


74061665 


1 


133 


74061162 


1 


134 


74061163 


1 


135 


74061174 


1 


136 


74061164 


1 


137 


74061165 


1 


138 


74061175 


1 


139 


74055960 


1 


140 


74061666 


1 


141 


74061662 


1 


142 


74061664 


1 


143 


74061660 


1 


144 


74061643 


1 



INJECTION PUMP PARTS (Continued) 
DESCRIPTION 

PISTON, advance 

SLEEVE, governor thrust 

WASHER, governor thrust sleeve 

WEIGHT, governor 

RETAINER ASSY. , governor 

SCREW, leaf spring 

SPRING, leaf 

SCREW, leaf spring 

ROLLER, cam 

SHOE, cam roller(-. 508mm)(-. 020") > 

SHOE, cam roller(-. 381mm)(-. 015") I Use as 

SHOE, cam roller(-. 127mm)(-. 010") J required 
(Used on Pump No. 74321882 only) 
□ CUSHION 

RETAINER, cushion 
DRING, retaining "E" clip 

VALVE, delivery 

SPRING, delivery valve 

STOP, delivery valve 

SCREW, delivery valve 

RING, cam 
DSEAL, hydraulic head 

HEAD ASSY. (Includes rotor, plungers, 3 screws, 
1 vent wire and item 125) 
DSEAL, transfer pump 

RETAINER, rotor 

CONNECTOR, fuel line 

SCREW, locking plate 

PLATE, locking 



LINER, transfer pump 

BLADE, transfer pump 

SPRING, transfer pump blade 

RING, inner locating 

ROLL PIN 
DSEAL, regulating piston 

REGULATOR ASSY. , transfer pump 
DSEAL, inlet filter screen 

PISTON, regulating 

SPRING, regulating 

PLUG ASSY., end plate adjustment 

RING, screen retainer 

SCREEN, inlet filter 

PLATE, transfer pump pressure 

CAP, transfer pump end 

GASKET KIT, pump (Includes items 11,36,51,52,53, 
60,63,64,66,68,70,73,74,89,100,112,114,121, 
123, 134 and 136)(Sufficient quantity for complete 
overhaul) 

□ Components of item 144 



SERVICE MANUAL 
FORM 73112988 



12-33 



(Revised June 1979) 




SERVICE MANUAL 
FORM 73112988 



INJECTION PUMP PARTS 
12-34 



T-80630 



(Added June 1979) 



INJECTION PUMP PARTS 
USAGE: 545-B, 605 -B Wheel Loader (Model 649T Engine with aneroid}* 



f 



c 



ITEM 



1 
2 
3 

4 
5 
6 
7 
8 

9 
10 
11 
13 
14 
15 
16 
17 
18 
19 
20 
21 
22 
23 
24 
26 
27 
28 



29 
30 
31 
32 
33 
34 
35 
36 
37 
38 
39 
40 
41 
42 
43 
44 
45 
46 
47 



PART NO, 

74008551 

74008552 

70910345 

74061140 

74062193 

70925995 

74061141 

74061142 

74061135 

74061134 

74062187 

74061133 

74061470 

74062050 

74062183 

74051559 

74049532 

74048639 
74052915 
74061670 
74061178 
74054579 
74048627 
74049533 
74048635 
74061168 
74061836 
74048624 



74059171 
74062261 
74053267 
70906957 
74053266 
74055293 
74062198 
74048630 
74061206 
74059170 
74061744 
74051412 
74051413 
74054594 
74056486 
74369478 
74056484 
74056799 
74051409 



QTY. DESCRIPTION 

1 PUMP ASSY. , 545-B (Includes items 1 thru 160) 

1 PUMP ASSY. , 605-B (Includes items 1 thru 160) 

1 NUT, hub retaining 

1 WASHER, hub retaining 

1 HUB, gear 

1 RING, retaining 

1 WASHER, drive shaft spring 

1 BEARING, ball 

1 PIN, spring, drive shaft 

1 RING, bearing shoulder 

1 SHAFT, drive 

1 RING, seal retaining 

2 SEAL, drive shaft 

2 SCREW, head locking 
1 SEAL, pump flange 

1 CLIP, shaft retainer 

1 LEVER, throttle shaft 

1 CAM, shut -off 

1 SHIM, metering valve 

1 SPRING, metering valve 

1 VALVE, metering valve 

1 ARM ASSY. , metering valve 

1 GUIDE, idling spring 

1 SPRING, idling 

1 RETAINER, spring 

1 ARM, governor 

1 SPRING, governor control (Blue-Blue) 

1 SPRING, governor linkage 

1 HOOK ASSY. , governor linkage (Includes items 29,30, 

37, 38) 
1 LINK ASSY. , adjusting 

1 HOOK, governor linkage 

3 WASHER, plain 

3 LOCKWASHER, cover screw 

3 SCREW, cover 

CONNECTOR ASSY. , return line 

COVER, governor control 

GASKET, governor cover 

WASHER, adjusting link 

SCREW, adjusting link 

SCREW, throttle lever spring 

RETAINER, throttle lever spring 

SPRING, throttle lever 

LEVER ASSY. , throttle 

ARM, adjusting spacer 

SCREW, spacer 

SPACER, throttle lever 

SCREW, low idle adjusting 

NUT, low idle adjusting screw 



c 



(Continued) 
12-35 



(Revised January 1981) 



INJECTION PUMP PARTS (Continued) 



:em 


PART NO. 


QT 


48 


74061716 


1 


49 


74058951 


1 


50 


74058950 


1 


51 


74053375 


2 


52 


74369878 


2 


53 


74050910 


2 


54 


74048642 


2 


55 


74048636 


1 


56 


74369429 


2 


57 


74369428 


1 


58 


74061192 


2 


59 


74048603 


1 


60 


74048604 


1 


61 


74059271 


1 


62 


74061589 


1 


63 


74061170 


1 


64 


74054589 


1 


65 


74059066 


1 


66 


74054585 


1 


67 


74059067 


1 


68 


743695 95 


1 


69 


74061130 


1 


70 


74051365 


1 


71 


74061131 


1 


72 


74051378 


1 


73 


74048650 


1 


74 


74369878 


1 


75 


74054582 


1 


76 


74054583 


1 


76A 


74052917 


2 


77 


74061409 


2 


78 


74048632 


2 


80 


70912739 


1 


81 


74369478 


1 


82 


74048647 


1 


83 


70906957 


1 


84 


74061602 


1 


85 


74061593 


1 


88 


74054583 


1 


89 


74369878 


1 


90 


74061179 


1 


91 


74061127 


1 


92 


74061169 


2 


93 


74061873 


1 


94 


74054589 


1 


95 


74062149 


1 


96 


74059395 


1 


96A 


74059397 


1 


97 


74059667 


1 


99 


74061128 


1 



DESCRIPTION 

SHAFT ASSY. , throttle 

NUT, high idle adjusting screw 

SCREW, high idle adjusting 

WASHER, throttle shaft seal 

SEAL, throttle shaft 

SEAL, pivot shaft 

NUT, pivot shaft 

SHAFT , governor arm pivot 

SCREW, name plate 

PLATE, name 

SCREW, timing line cover 

COVER, timing line 

GASKET, timing line cover 

PLUG, piston (spring) 

HOUSING ASSY. , pump 

SEAL, advance piston hole plug 

SEAL, advance piston hole plug 

PIN, advance 

SEAL, advance screw hole plug 

PLUG, advance screw hole 

SEAL, head locating screw 

SCREW, head locating 

SEAL, head locating screw 

PLUG, head locating screw 

STUD, guide 

WASHER, guide stud 

SEAL, torque screw 

SCREW, torque 

NUT, torque screw 

CAP, cover adjusting screw 

NUT, shut -off arm adjusting screw 

SCREW, shut-off arm adjustment 

WASHER, adjusting shut-off position screw 

SCREW, adjusting shut- off position 

SCREW, adjusting shut- off return 

WASHER, adjusting shut-off return 

ARM ASSY. , adjusting shut-off 

SHAFT ASSY. , shut-off 

NUT, advance adjusting screw 

SEAL, advance adjusting screw 

PLUG, piston hole (power) 

VALVE, reed 

SCREW, reed valve 

SEAL, advance piston hole 

SEAL, advance piston hole 

SCREW, advance adjusting 

GUIDE, advance adjusting screw 

RING, spring retaining 

SPRING, outer advance (Yellow- Yellow) 

RING, advance piston 



( 



c 



(Continued) 
12-36 



(Revised December 1979) 



( 



c 



[TEM 


PART NO. 


QT 


100 


74059064 


1 


101 


74061677 


1 


102 


74061852 


1 


103 


74061148 


1 


104 


74061149 


6 


105 


74061150 


1 


106 


74055970 


1 


107 


74055890 


2 


108 


74055969 


1 


109 


74369436 


4 


110 


74061157 


4 




74061590 


4 


112 


74061156 


6 


113 


74061155 


3 


114 


74061154 


6 


116 


74062211 


1 


117 


74061188 


1 


118 


74061161 


1 


119 


74061160 


1 


120 


74062051 


1 


121 


74369444 


1 


122 


74061152 


1 


123 


74061661 


1 


124 


74061663 


2 


125 


74061195 


6 


126 


74061187 


1 


127 


74062282 


1 


129 


74061172 


1 


130 


74059733 


4 


131 


74055958 


2 


132 


74061665 


1 


133 


74061162 


1 


134 


74061163 


1 


135 


74061174 


1 


136 


74061164 


1 


137 


74061165 


1 


138 


74061175 


1 


139 


74055960 


1 


140 


74061666 


1 


141 


74061662 


1 


142 


74061664 


1 


143 


74061660 


1 


144 


74053829 


2 


145 


74060067 


3 


146 


74060058 


1 


147 


70912739 


1 


148 


74051383 


2 


149 


74061205 


1 


150 


74049437 


2 



»1")J 



Use as 
Required 



INJECTION PUMP PARTS (Continued) 

DESCRIPTION 

SEAL, piston ring 

PISTON, advance 

SLEEVE, governor thrust 

WASHER, governor thrust sleeve 

WEIGHT, governor 

RETAINER ASSY. , governor 

SCREW, leaf spring 

SPRING, leaf 

SCREW, leaf spring 

ROLLER, cam 

SHOE, cam roller (-. 508mm)(-. 02 

SHOE, cam roller (-. 38lmm)(-. 05 

CUSHION 

RETAINER, cushion 

RING, retaining "E" clip 

VALVE, delivery 

SPRING, delivery valve 

STOP, delivery valve 

SCREW, delivery valve 

RING, cam 

SEAL, hydraulic head 

HEAD ASSY. (Includes rotor, plungers, 3 screws 

1 vent wire and item 125) 
SEAL, transfer pump 
RETAINER, rotor 
CONNECTOR, fuel line 
SCREW, locking plate 
PLATE, locking 
LINER, transfer pump 
BLADE, transfer pump 
SPRING, transfer pump blade 
RING, inner locating 
ROLL PIN 

SEAL, regulating piston 
REGULATOR ASSY. , transfer pump 
SEAL, inlet filter screen 
PISTON, regulating 
SPRING, regulating 
PLUG ASSY. , end plate adjustment 
RING, screen retainer 
SCREEN, inlet filter 
PLATE, transfer pump pressure 
CAP, transfer pump end 
NUT, lock terminal contact 
WASHER, terminal contact 
WIRE ASSY. , terminal ground 
LOCKWASHER, terminal contact 
WASHER, terminal insulating 
LOCKWASHER, cover screw 
NUT, terminal contact 



( 



SERVICE MANUAL 
FORM 73112988 



(Continued) 



12-37 



(Added June 1979) 



ITEM 


PART NO. 


QT 


151 


74062326 


1 


152 


74369502 


2 


152A 


74062190 




153 


74060214 




154 


74369496 




155 


74062191 




156 


74060210 




157 


74369878 




158 


74060212 




159 


74060211 




160 


74060213 




161 


74062322 




162 


74061592 


4 


163 


70906957 


4 


164 


74061593 


1 


165 


74061594 


1 


166 


74061595 


1 


167 


74061596 


1 


168 


74061597 


2 


169 


74061643 


1 



INJECTION PUMP PARTS (Continued) 
QTY. DESCRIPTION 



COIL ASSY. , shut-off (24V E. T. R. )(Includes solenoid 
which is not serviced separately and items 144, 145, 
148,150 and 152 thru 155) 

TUBE 

PLUNGER, solenoid (Not illustrated) 

SLEEVE, coil arm spring 

SPRING 

ARM ASSY. , solenoid 

RING, over -ride retaining 

SEAL, over -ride rod 

WASHER, over -ride guide 

GUIDE ASSY. , over -ride 

ROD, over -ride 

ANEROID ASSY. (Serviced only as a unit. (Includes 
Cap Assy. , Piston'Assy. , Shims, Spring and Body 
which are not serviced separately) (Also includes 
162,163 and 164) 

SCREW, bracket mounting 

WASHER, bracket mounting 

BRACKET, aneroid mounting 

NUT, body assembly retaining 

BOOT, aneroid 

ROD, operating 

RING, retaining 

GASKET KIT, pump (Includes items 11,36,51,52,53, 
60,63,64,66,68,70,73,74,89,100,112, 114, 121, 123, 
134, 136 and 157)(Sufficient quantity for complete 
overhaul) 



r 



( 



Components of item 169 



SERVICE MANUAL 
FORM 73112988 



12-38 



(Added June 1979) 



( 



CONVERSION TABLES 

DECIMAL AND METRIC EQUIVALENTS OF FRACTIONS OF AN INCH 



Inches 



Fractions 



Decimals 



♦Norn. 
Dec. 



Milli- 
meters 



Inches 



Fractions 



Decimals 



>Nom. 
Dec. 



Milli- 
meters 



c 



1/64- 

3/64- 

5/64- 

7/64- 

9/64- 

11/64 

13/64- 

15/64- 

17/64- 

19/64- 

21/64- 

23/64- 

25/64- 

27/64- 

29/64- 

31/64- 



1/32- 



1/16 — 



3/32 



1/8- 



5/32- 



3/16 — 



7/32- 



1/4- 



9/32- 



5/16 — 



11/32- 



3/8 



13/32 



7/16 — 



15/32 



1/2- 



.015625 

,03125 

.046875 

.0625 

.078125 

.09375 

.109375 

.125 

.140625 

.15625 

.171875 

.1875 

.203125 

.21875 

.234375 

.250 

.265625 

.28125 

.296875 

.3125 

.328125 

.34375 

.359375 

.375 

.390625 

.40625 

.421875 

.4375 

.453125 

.46875 

.484375 

.500 



.02 
.03 
.05 
.06 
.08 
.09 
.11 
.12 
.14 
.16 
.17 
.19 
.20 
.22 
.23 
.25 
.27 
.28 
.30 
.31 
.33 
.34 
.36 
.38 
.39 
.41 
.42 
.44 
.45 
.47 
.48 
.50 



.397 

.794 

1.191 

1.588 

1.984 

2.381 

2.778 

3.175 

3.572 

3.969 

4.366 

4.763 

5.159 

5.556 

5.953 

6.350 

6.747 

7.144 

7.541 

7.938 

8.334 

8.731 

9.128 

9.525 

9.922 

10.319 

10.716 

11.113 

11.509 

11.906 

12.303 

12.700 



33/64 
35/64 
37/64 
39/64 
41/64 
43/64 
45/64 
47/64 
49/64 
51/64 
53/64 
55/64 
57/64 
59/64 
61/64 
63/64 





11/ oZ 


9/16 — 


nn/oo 




5/8 


°1 /T> 


41/ Ol* 


11/16- 


t}n /nty 


d,6f Od, 


3/4 


05/30 




13/16- 


on /*>o 


£. 1/ 04 


7/8 


°o/**o 




15/16- 


«M /•»*> ,„ ,_ 


nil/ nift ' "' " — 




1 



.515625 
.53125^ 
.546875 
.5625 
.578125 
.59375 
.609375 
.625 
.640625 
.65625 
.671875 
.6875 
.703125 
.71875 
.734375 
.750 
.765625- 
.78125 
.796875 
.8125 
.828125 
.84375 
.859375 
.875 
.890625 
.90625 
.921875 
.9375 
.953125 
.96875 
.984375 
1.000 



.52 
.53 
.55 
.56 
.58 
.59 
.61 
.62 
.64 
.66 
.67 
.69 
.70 
.72 
.73 
.75 
.77 
.78 
.80 
.81 
.83 
.84 
.86 
.88 
.89 
.91 
.92 
.94 
.95 
.97 
.98 
1.00 



13.097 
13.494 
13.891 
14.288 
14.684 
15.081 
15.478 
15.875 
16.272 
16.669 
17.066 
17.463 
17.859 
18.256 
18.653 
19.050 
19.447 
19.844 
20.241 
20.638 
21.034 
21.431 
21.828 
22.225 
22.622 
23.019 
23.416 
23.813 
24.209 
24.606 
25.003 
25.400 



c 



VOLUME AND WEIGHT CONVERSION 
CONSTANTS - U.S. TO METRIC 

Pints x .4732 = Liters 
Quarts x .9463 = Liters 
Gallons x 3.7853 = Liters 
Pounds x .4536 = Kilograms 
Cubic Yards x .7645 = Cubic Meters 



TORQUE & PRESSURE 
CONVERSION 
CONSTANTS - 

lb. ft. x 0.1383 = m-kg 
lb. in. x 1. 1521 = cm -kg 
psi x 0. 0703= kg/cm 2 



LENGTH CONVERSION 
CONSTANTS - U.S. TO METRIC 

Inches x 25.400 = Millimeters 
Inches x .0254 = Meters 
Feet x .3048 = Meters 
Statute Miles x 1.60935 = Kilometers 



♦Nominal decimals are used in place of fractions of an inch, with exception of such items as bolts, screws, washers, 
tubing, wire, etc. 



( 



c